Battery Feedthrough Assembly for High-Current Sealing Integrity
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Solution Overview
Problem
Existing feedthroughs for metal-ion electrochemical accumulators, particularly those using aluminum-based materials, face issues with deformation during assembly due to crimping, leading to poor mechanical integrity and potential leakage, especially when high currents are required.
Innovation Solution
A feedthrough design featuring a conductive male part and female part made of aluminum-based alloys, with a tight fit between a projecting portion of the male part and a blind hole in the female part, using specific aluminum grades for mechanical strength and chemical compatibility, and incorporating a conduit to evacuate air during assembly to ensure a robust and sealed connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If aluminum-based materials are used for feedthrough components, then chemical compatibility with aluminum-based electrodes is improved, but deformation during crimping assembly occurs leading to poor mechanical integrity
Solution Approach 1:
The feedthrough assembly uses a composite structure combining aluminum-based components (for chemical compatibility with aluminum electrodes) and copper-based components (for mechanical strength and electrical conductivity). The aluminum ferrule contacts the aluminum wire internally, while the copper housing provides structural support and external contact, creating a hybrid system that leverages the advantages of both materials.
Solution Approach 2:
The feedthrough is divided into functionally distinct segments: an aluminum ferrule portion for internal contact with the aluminum wire (providing chemical compatibility), and a copper housing portion for external contact and structural support (providing mechanical strength). This segmentation allows each component to be optimized for its specific function without compromise.
2Power
If high currents are required, then battery capacity is improved, but heat generation and mechanical stress increase causing potential leakage
Solution Approach 1:
The aluminum ferrule acts as an intermediary component between the aluminum wire and the copper housing. It provides a chemically compatible interface for the aluminum wire while transferring mechanical and electrical loads to the copper housing, which is better suited for handling high current stresses and heat generation.
Solution Approach 2:
The feedthrough design incorporates specific geometric parameters (thread pitch, crimping dimensions, wall thickness) and material properties (electrical conductivity, thermal conductivity, mechanical strength) that are optimized to handle high current applications. The copper housing's superior electrical and thermal conductivity helps manage heat generation from high currents.
3Reliability
If tight sealing is required, then leakage prevention is improved, but assembly complexity increases due to multiple components
Solution Approach 1:
The feedthrough merges multiple functions into a single integrated component assembly: the aluminum ferrule and copper housing are permanently joined through crimping and threading to form a unified feedthrough unit that provides both sealing and electrical connection functions in one assembly operation.
Data Source
Figure 1~3
Figure 4~7
Figure 8~9
AI summary
The present invention relates to a feedthrough (1) forming a terminal for an electrochemical metal-ion battery, provided through an aperture (32) opening out on either side of a wall (3) having two opposing surfaces (30, 31), and comprising: an electrically conductive male part (7) and an aluminum alloy female part (8), a portion (71) of the male part (7) being tight-fitted into a blind hole (81) of the female part (8).