Power Battery Top Cap Connection Block
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Solution Overview
Problem
The challenge in forming a stable power battery top cap structure lies in welding copper and aluminum materials together, as their differing melting points and specific heat capacities make ultrasonic or laser welding difficult, leading to fluctuations in contact electrical resistance due to external factors like shaking and impacting.
Innovation Solution
A power battery top cap structure is designed with a first electrode assembly and a top cap piece, featuring a compound portion bonded to a main body of different base metals, where the connection section is welded through a process like laser welding, forming a stable power transmission surface by ensuring a high bonding rate and tensile strength, thus avoiding fluctuations in contact electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper and aluminum materials are welded together using ultrasonic or laser welding, then the power battery top cap structure can be formed, but the welding quality is poor and contact electrical resistance fluctuates due to different melting points and specific heat capacities
Solution Approach 1:
The connection block is segmented into multiple portions: a first portion made of aluminum material matching the busbar, and a second portion made of copper material matching the electrode column. This segmentation allows each portion to be optimally matched with its corresponding component, avoiding direct welding between dissimilar metals while maintaining electrical conductivity and mechanical strength.
Solution Approach 2:
The connection block uses a composite structure with different base metals (aluminum and copper) in different portions. The first portion uses aluminum material that matches the busbar material, while the second portion uses copper material that matches the electrode column material, creating a composite connection block that optimizes both electrical conductivity and welding compatibility.
2Ease of manufacture
If the same material is used for both connection blocks to simplify welding, then manufacturing is easier, but the structural complexity increases to accommodate material transitions
Solution Approach 1:
Different portions of the connection block have different material compositions tailored to their specific functions. The first portion uses aluminum material optimized for welding with the aluminum busbar, while the second portion uses copper material optimized for connection with the copper electrode column. This local differentiation of material properties simplifies the overall manufacturing process by eliminating the need for complex material transition structures.
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 solution effectively stabilizes power transmission by creating a metallurgical bond with a bonding rate of at least 90%, enhancing the structural integrity and reducing contact electrical resistance fluctuations, even under external forces.
Implementation Method 1
The connection section and the compound portion are welded together. Preferably, the connection section and the compound portion are connected via laser welding.
Implementation Method 2
The compound portion is bonded with the main body, and the compound portion includes a first connection hole. The bonding rate is at least 90%.
Data Source
AI summary
A top cap structure for a power battery includes a first electrode assembly and a top cap piece. The first electrode assembly includes a first electrode column and a first connection block. The first connection block includes a main body and a compound portion that are bonded together. A base metal material of the main body is different from the base metal materials of the first electrode column and the compound portion. The compound portion includes a first connection hole and the main body includes a second connection hole. A top portion of the first electrode column includes a connection section. The connection section passes through the top cap piece, the second connection hole, and the first connection hole, and extends from the first connection hole. The connection section and the compound portion are welded together. The connection section is riveted to the second connection hole.