Battery Cell Conductive Post Structure for Stronger Cu-Al Bonding
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Solution Overview
Problem
The bonding strength between different metal layers in composite poles is limited, leading to detachment and failure of battery cores, particularly in laser welding processes due to differences in melting points of materials like copper and aluminum.
Innovation Solution
A conductive structure with a first-metal post and a second-metal layer bonded together, where the second-metal layer wraps and extends from the first end to the second end, increasing the bonding area and enhancing the bonding strength through a specific design with gaps, extensions, and varying thicknesses to improve adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a composite pole with two metal layers is designed to reduce welding difficulty, then the ease of manufacture is improved, but the bonding strength between metal layers becomes limited causing detachment
Solution Approach 1:
The patent transitions from a conventional two-layer composite pole structure to a multi-layer structure with at least three metal layers. This dimensional change in layering provides additional bonding interfaces and distributes mechanical stresses across multiple boundaries, thereby enhancing overall bonding strength while maintaining ease of manufacture through modular layer assembly.
Solution Approach 2:
The patent employs composite materials by selecting specific metal combinations for different layers, including at least one non-ferrous metal layer and at least one ferrous metal layer. This composite approach allows optimization of each layer's properties for specific functions while achieving strong inter-layer bonding through controlled metallurgical interfaces.
2Use of energy by moving object
If laser welding is used to join copper pole and aluminum terminal pressing block to reduce cost and weight, then the use of energy is reduced, but welding reliability deteriorates due to melting point differences causing cracking
Solution Approach 1:
The patent introduces an intermediate metal layer between the copper pole and aluminum terminal pressing block. This intermediary layer acts as a transition zone with intermediate melting point and thermal conductivity, mediating the thermal and mechanical stresses during laser welding. The intermediate layer prevents direct contact between copper and aluminum, eliminating cracking caused by their large melting point difference while maintaining energy efficiency of laser welding.
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 enhanced bonding area and strength reduce the risk of detachment, ensuring improved overcurrent capacity and reliability of the conductive structure.
Implementation Method 1
a second-metal layer bonded to a surface of the first-metal post, the second-metal layer wrapping the first end and extending toward the second end
Data Source
AI summary
A conductive structure and a manufacturing method, a cover plate assembly, and a battery cell are provided. The conductive structure includes a metal post including a first end and a second end opposite to each other. A metal layer bonded to a surface of the metal post. The metal layer wraps the first end and extends toward the second end. The metal layer bonded to the surface of the first end of the metal post is arranged to extend from the surface of the first end of the metal post to the second end.