Battery Terminal Embedded Joint Structure to Prevent Weld Cracking
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Solution Overview
Problem
Friction welding of metal parts with different materials often results in thermal stress, welding deformation, and increased brittleness, leading to cracking and reduced safety of battery terminals.
Innovation Solution
A terminal design that embeds protruding and recessed portions of metal parts to form a bonding surface, increasing the radial length of the bonding surface and enhancing the bonding strength between metal parts, thereby reducing the risk of fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding is used to connect metal parts of different materials, then the metal parts can be fixedly connected, but thermal stress is generated causing welding deformation and cracking
Solution Approach 1:
The connection structure is segmented into protruding portions and recessed portions that interlock with each other. This segmentation allows the connection to be distributed across multiple contact points rather than a single welded joint, reducing thermal stress concentration and preventing cracking while maintaining bonding strength.
Solution Approach 2:
The protruding portions of one metal part are embedded into the recessed portions of the other metal part, creating a nested interlocking structure. This nesting design increases the bonding surface area and distributes mechanical stresses, eliminating the need for friction welding and preventing thermal stress-induced cracking.
2Strength
If friction welding is used to connect metal parts, then connection is achieved, but welding deformation occurs due to thermal stress
Solution Approach 1:
The connection interface is divided into multiple protruding and recessed portions that interlock, distributing the connection across several points. This segmentation eliminates the need for extensive welding, thereby preventing welding deformation while maintaining connection strength.
Solution Approach 2:
The thermal-based friction welding process is replaced with a mechanical interlocking system consisting of protruding and recessed portions. This mechanical substitution eliminates thermal stress and associated welding deformation while achieving secure connection between metal parts.
3Strength
If friction welding is used to connect different metal materials, then connection is achieved, but the welding surface becomes brittle and prone to cracking
Solution Approach 1:
The bonding interface is segmented into multiple protruding and recessed portions that create a distributed connection. This segmentation avoids the creation of large brittle heat-affected zones associated with friction welding, preventing cracking while maintaining bonding strength.
Solution Approach 2:
The friction welding process that creates brittle heat-affected zones is replaced with a mechanical interlocking system. The protruding and recessed portions create a cold-formed mechanical connection that eliminates thermal brittleness and cracking while achieving reliable bonding.
Data Source
AI summary
A terminal, a top cover structure, a battery cell, a battery module, and a battery pack are disclosed, and the present application relates to the technical field of batteries, and. The terminal includes a first metal part and a second metal part connected to each other. a protruding portion is arranged at one of the first metal part and the second metal part, a first recessed portion is arranged at another one, the protruding portion is connected to the first recessed portion in an embedded manner; and an edge of one end of the second metal part extends outward to form an extension edge, a second recessed portion is arranged at the first metal part, the extension edge is embedded in the second recessed portion.