Battery Top Cover Assembly With Welded Terminal Posts and Low-Heat Fixing
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Solution Overview
Problem
Existing battery top cover assemblies face issues such as deformation due to excessive heat generation during laser welding, leading to high rejection rates and material waste from copper-aluminum composite strips, increasing production costs.
Innovation Solution
A battery top cover assembly with welded terminal posts featuring a copper-aluminum structure assembled through ultrasonic or laser welding, using a welding interface layer and riveting convex portions to minimize deformation and reduce material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is used to fix auxiliary mounting parts to the top cover plate, then the terminal posts are securely fixed, but excessive heat generation causes deformation of the top cover plate
Solution Approach 1:
The patent divides the terminal post structure into multiple components: the terminal post body, auxiliary mounting parts with through holes, and riveting convex portions. This segmentation allows the welding process to be localized to small specific areas rather than large surfaces, reducing overall heat input and minimizing deformation of the top cover plate while still achieving secure fixation.
Solution Approach 2:
The patent implements localized welding by creating riveting convex portions only at specific mounting locations on the terminal posts. This local quality approach concentrates the welding heat to discrete points rather than distributing it across the entire top cover plate, thereby securing the terminal posts effectively while preventing excessive heat-induced deformation of the plate.
2Reliability
If copper-aluminum composite strips are used to form terminal posts through stamping, then terminal posts with required electrical conductivity are produced, but excessive waste materials are generated and raw material utilization rate is low
Solution Approach 1:
The patent segments the terminal post structure into a copper part (for electrical conductivity) and an aluminum part (for structural properties and riveting). This segmentation allows each material to be used only where needed, eliminating the material waste associated with forming entire terminal posts from copper-aluminum composite strips while maintaining the required electrical conductivity at the contact surfaces.
Solution Approach 2:
The patent employs a composite structure where a copper part is welded to an aluminum part. The copper part provides the necessary electrical conductivity for terminal post function, while the aluminum part facilitates riveting and structural integration. This composite material approach optimizes material utilization by assigning each material to its most suitable function, reducing overall material waste compared to using copper-aluminum composite strips throughout.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly method improves production yield and quality by preventing top cover plate deformation, enhances sealing performance, and reduces manufacturing costs through efficient material utilization.
Implementation Method 1
a welding method by which the aluminum part is welded and fixed to the top of the copper part is laser welding or ultrasonic welding
Implementation Method 2
a welding method by which the aluminum part is welded and fixed to the top of the copper part is laser welding or ultrasonic welding
Data Source
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AI summary
Disclosed is a battery top cover assembly with welded terminal posts, which includes a top cover plate, terminal post structures, caps, sealing rings, upper insulating parts, and a lower insulating part. Two ends of the top cover plate are provided with mounting holes in the length direction; a terminal post structure is mounted in each mounting hole through a cap, a sealing ring, an upper insulating part, and the lower insulating part; a terminal post portion of the terminal post structure in one mounting hole includes a copper part and an aluminum part; and the terminal post structure in the other mounting hole is an aluminum terminal post, thereby improving production quality and yield and reducing production cost.