Composite Battery Pole Clamping Structure Against Layer Separation
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Solution Overview
Problem
Composite poles in battery cells, made of different metal layers, face bonding strength issues leading to separation and failure, particularly due to differences in thermal expansion and welding difficulties.
Innovation Solution
A conductive module with a first-metal post and a second-metal layer bonded together, featuring a clamping portion clamped between the post and a terminal pressing block, enhancing bonding through interference fit, press riveting, and laser welding, with a support surface to improve stability and reduce separation risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite pole with different metal layers is used to reduce welding difficulties and cost, then manufacturing cost and weight are reduced, but bonding strength between metal layers is limited causing separation
Solution Approach 1:
The pole is segmented into multiple metal layers (first metal layer and second metal layer) with different materials, allowing each layer to be optimized for specific functions while maintaining overall structural integrity and reducing welding difficulties
Solution Approach 2:
The second metal layer is wrapped around and bonded to the first metal layer, creating a nested structure where the clamping portion is夹持 between the first metal layer and the terminal pressing block, enhancing bonding strength through multi-point constraint
2Ease of manufacture
If friction welding or stamping is used to bond metal layers, then bonding is achieved, but bonding strength is limited causing metal layers to fall off
Solution Approach 1:
The clamping portion is pre-formed on the second metal layer before assembly, enabling it to be effectively夹持 between the first metal layer and terminal pressing block, ensuring reliable bonding before final assembly
Solution Approach 2:
The clamping portion acts as an intermediary element that transfers and distributes bonding forces between the first metal layer and terminal pressing block, enhancing overall bonding reliability through distributed stress
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 solution effectively increases bonding strength and reduces the risk of metal layers separating, improving the conductive module's reliability and overcurrent capability while reducing production costs and weight.
Implementation Method 1
The through hole is in interference fit with the pole
Implementation Method 2
the terminal pressing block is fixed to the pole by press riveting
Implementation Method 3
a hole wall of the through hole is welded to the pole
Implementation Method 4
the terminal pressing block is supported on the support surface
Data Source
AI summary
A conductive module, a cover plate assembly, and a battery cell are provided. The conductive module includes a pole, where the pole includes a metal post and a metal layer bonded on a surface of the metal post. The metal layer includes a clamping portion; and a terminal pressing block connected to the pole. The clamping portion is clamped between the metal post and the terminal pressing block. The pole is provided to include the metal post and the metal layer, and the pole is connected to the terminal pressing block. A portion (i.e., the clamping portion) of the metal layer is clamped between the metal post and the terminal pressing block.