Secondary Battery Terminal Plates Dissimilar Metal Welding
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Solution Overview
Problem
Existing secondary battery designs face challenges in efficiently connecting and insulating electrode terminals, particularly when using different materials, which can lead to electrical and mechanical connectivity issues and reduced welding quality.
Innovation Solution
The design incorporates a first and second electrode terminal configuration with specific insulators and seal gaskets, using copper or copper alloy for the first terminal and aluminum or aluminum alloy for the upper terminal plate, connected via diffusion or laser welding, and bus bars made of aluminum or aluminum alloy to enhance electrical and physical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different materials (copper and aluminum) are used for electrode terminals, then electrical conductivity and welding quality are improved, but manufacturing complexity increases due to the need for diffusion welding processes
Solution Approach 1:
The patent applies composite materials by combining copper (for the first terminal with high electrical conductivity) and aluminum (for the upper terminal plate with good weldability and lighter weight). This composite structure allows each material to发挥 its advantages: copper provides excellent electrical conductivity for efficient current collection, while aluminum provides good welding characteristics and reduced weight. The diffusion welding process creates a metallurgical bond between these dissimilar metals, achieving reliable electrical connections while maintaining manufacturing feasibility through controlled thermal diffusion processes.
2Reliability
If multiple insulators and seal gaskets are added to ensure proper insulation and sealing, then electrical insulation and sealing reliability are improved, but device complexity increases
Solution Approach 1:
The patent employs insulators and seal gaskets as intermediary elements that mediate between the conductive terminal components and the surrounding environment. The lower insulator positioned between the first terminal and cap plate, along with the seal gasket, creates electrical isolation and environmental sealing without requiring direct modification of the terminal structure itself. These intermediary components provide necessary insulation and sealing functions while maintaining a relatively simple overall design, as they can be integrated into the existing terminal assembly without adding significant structural complexity.
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
This configuration improves the electrical and mechanical connections between electrode terminals, enhances welding quality, and allows for the use of different materials while maintaining efficient battery performance.
Implementation Method 1
The upper terminal plate and the lower terminal plate may be connected to each other by a diffusion weld
Implementation Method 2
the first terminal and the lower terminal plate may be connected to each other by a laser weld
Data Source
AI summary
A secondary battery, including an electrode assembly including a first electrode, a second electrode, and a first electrode tab and a second electrode tab connected to the first electrode and the second electrode, respectively; a case including a receiving part that receives the electrode assembly, the case having an open side; a cap plate sealing the open side of the case; and a first electrode terminal and a second electrode terminal passing through the cap plate, the first electrode terminal being connected to the first electrode tab, the second electrode terminal being connected to the second electrode tab, the first electrode terminal including a first terminal, a lower terminal plate provided at a top end of the first terminal, and an upper terminal plate provided at a top end of the lower terminal plate, the first electrode tab being connected to a bottom end of the first terminal.