Composite Battery Terminal Post for Shorter Current Paths
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Solution Overview
Problem
Composite poles made of different metal layers suffer from insufficient overcurrent capability due to a long current path and high resistance, exacerbated by welding difficulties between materials like copper and aluminum.
Innovation Solution
A conductive structure comprising a first-metal post with a second-metal layer bonded to its surface, where the second-metal layer extends from one end to the other, increasing the bonding area and shortening the current flow path, with a ratio of their distances and thicknesses optimized to enhance conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a composite pole with two metal layers is used, then welding difficulty is reduced, but overcurrent capability becomes insufficient due to long current path and high resistance
Solution Approach 1:
The patent transitions from a planar two-layer composite structure to a three-dimensional structure where the second metal layer wraps around the first metal post. This dimensional change allows the conductive layer to extend along the axial direction, shortening the current path while maintaining the composite material benefits for welding.
Solution Approach 2:
The patent uses a composite structure of two different metals (first metal post and second metal layer) to combine the advantages of each material. The first metal provides structural support and cost-effectiveness, while the second metal provides excellent conductivity and weldability, resolving the contradiction between manufacturing ease and electrical performance.
2Area of stationary object
If the second-metal layer extends further along the axial direction, then bonding area increases, but current path length may increase reducing overcurrent capability
Solution Approach 1:
The patent optimizes the axial extension length of the second metal layer as a critical parameter. By controlling this dimension, the design achieves the optimal balance between increasing bonding area (for structural integrity) and limiting current path length (for maintaining low resistance and high overcurrent capability).
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 conductive structure improves overcurrent capability by increasing the bonding area and reducing the current flow path length, while maintaining cost-effectiveness by using less expensive materials like aluminum for the first-metal post and copper for the second-metal layer.
Implementation Method 1
a second-metal layer bonded to a surface of the first-metal post
Implementation Method 2
a path of current flowing on the composite pole is long, a resistance of the composite pole is too large
Data Source
AI summary
A conductive structure, 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, and 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 is used to be connected to a tab. In an axial direction of the metal post, a distance from an end portion of the metal layer to an end surface of the second end is H1, a thickness of the metal post is D2, and a ratio of H1 to D2 is less than or equal to 0.8.