Battery Cell Pole Assembly for Copper-Aluminum Overcurrent Capacity
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Solution Overview
Problem
Existing battery cell poles with copper-aluminum composite structures have a reduced overcurrent capacity due to small fitting surfaces resulting from insufficient extruding force of copper on aluminum, leading to gaps and decreased conductivity.
Innovation Solution
A pole design with a first metal part and a second metal part, where the second metal part with higher material fluidity is embedded into the first metal part, increasing the extruding surface area and reducing gaps, using copper for the first part and aluminum for the second part, enhancing the combination reliability and overcurrent capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an interlocking structure is formed by upsetting between copper material and aluminum material, then the combination reliability is improved, but the fitting surface area is reduced
Solution Approach 1:
The patent applies nesting by forming an interlocking structure where the copper material is embedded into the aluminum material through upsetting. The inner wall of the copper material is inserted into the outer peripheral surface of the aluminum material, creating a nested configuration that enhances combination reliability while maintaining adequate fitting surface area for current transmission.
2Device complexity
If the fitting surface area between copper and aluminum is small, then the manufacturing complexity is reduced, but the overcurrent capacity is reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the geometric parameters of the interlocking structure, including the wall thickness of the copper material, the radius of the aluminum material, and the upsetting depth. These parameter adjustments ensure adequate fitting surface area for overcurrent capacity while maintaining manufacturing feasibility through conventional upsetting processes.
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 design improves the overcurrent capacity and reliability of the pole by increasing the contact surface area between copper and aluminum, while controlling material costs and weight, thus enhancing the overall performance and economy of the battery cell.
Implementation Method 1
material fluidity of the second metal part is greater than material fluidity of the first metal part
Data Source
AI summary
The present disclosure provides a pole, a cover plate assembly, and a battery cell. The pole includes a first metal part and a second metal part. The first metal part has a first inward part and a first outward part that is disposed on an inner wall of the first inward part. The second metal part includes a main body and a second outward part. A second inward part is disposed on an outer peripheral surface of the second outward part. The second outward part is embedded into the first inward part, and the first outward part is embedded into the second inward part. A side of the second inward part away from a bottom wall of the first inward part is represented as a first surface. And a gap is only disposed between the first outward part and the first surface.