Cold-Headed Copper-Aluminum Battery Pole for Low-Cost Top Covers
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Solution Overview
Problem
Existing battery top cover structures have high production costs due to low material utilization rates and complex processes, particularly with the use of copper-aluminum composite poles which are heavy and costly to manufacture.
Innovation Solution
A pole and top cover structure design featuring a copper-aluminum composite pole made through a cold heading process, with a sealing flange portion and connecting step formed by cold heading, achieving a high material utilization rate of 100% and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If copper-aluminum friction welding or copper-aluminum composite plate stamping is used to form copper-aluminum composite poles, then the weight of the top cover is reduced, but the material utilization rate is low and the process is complex, resulting in high cost
Solution Approach 1:
The pole is divided into two separate metal pillars (first metal pillar and second metal pillar) connected together, rather than using a complex copper-aluminum composite plate structure. This segmentation simplifies the manufacturing process while maintaining the weight reduction benefit.
Solution Approach 2:
The connecting step and sealing flange portion are merged into an integrated structure formed by cold heading process, eliminating the need for separate forming operations and reducing process complexity while achieving both connection and sealing functions.
2Productivity
If stamping process is used to manufacture poles, then the production efficiency is maintained, but the material utilization rate is only about 55% and the cost is high
Solution Approach 1:
The manufacturing process is changed from stamping to cold heading process. This parameter change in the forming method enables 100% material utilization rate while maintaining high production efficiency, as cold heading is a near-net-shape forming process with minimal material waste.
3Loss of substance
If copper-aluminum composite plate stamping is used, then the material utilization rate improves, but the process becomes complex and the cost increases
Solution Approach 1:
The process parameter is changed from composite plate stamping to cold heading of separate metal pillars. This simplifies the manufacturing process while achieving 100% material utilization rate, as cold heading is a simpler, more direct forming process.
Solution Approach 2:
Instead of using composite plate materials requiring complex stamping, the invention uses two separate metal pillars (copper and aluminum) connected together. This approach achieves the desired material properties with a simpler manufacturing process and higher material utilization.
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 design reduces production costs by improving material utilization and simplifying the manufacturing process, while also enhancing sealing and insulation performance between the pole and the cover assembly.
Implementation Method 1
The protruding portion is embedded in the recessed portion to form a joint surface
Implementation Method 2
A pole and top cover structure design featuring a copper-aluminum composite pole made through a cold heading process
Implementation Method 3
enhancing sealing and insulation performance between the pole and the cover assembly
Implementation Method 4
some negative poles use copper-aluminum composite poles to reduce the proportion of copper in the negative poles. Although this reduces the overall weight of the top cover
Data Source
AI summary
A pole (4), a top cover structure (100), a battery (1000), a battery module and a battery pack are provided. The pole includes a first metal pillar (41) and a second metal pillar (42) connected to each other. One end of the first metal pillar (41) is provided with a heading groove (411), and the other end of the first metal pillar (41) opposite to the first end is provided with a protruding portion (412). The second metal pillar (42) is provided with a recessed portion (421) recessed in a direction away from the heading groove (411). The protruding portion (412) is embedded in the recessed portion (421) to form a joint surface (43).