Composite Battery Pole Structure With Wrapped Metal Layer Bonding
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Solution Overview
Problem
Composite poles in batteries, composed of different metal layers, face issues with limited bonding strength, leading to detachment and failure due to differences in thermal expansion coefficients and welding difficulties, particularly affecting the negative pole.
Innovation Solution
A conductive structure with a first-metal post and a second-metal layer bonded to its surface, where the second-metal layer extends from the first end to the second end, increasing bonding area and incorporating an embedding manner to enhance adhesion, with features like gaps and supporting surfaces to improve stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a composite pole with multiple metal layers is used to reduce welding difficulty and cost, then the ease of manufacture improves, but the bonding strength between metal layers deteriorates
Solution Approach 1:
The second metal layer is wrapped around and embedded into the first metal post, creating a nested structure where one component is partially inserted into another. This embedding manner increases the bonding interface area and mechanical interlocking, thereby improving bonding strength while maintaining the composite structure's manufacturing advantages
Solution Approach 2:
The invention uses a composite structure of different metal materials (aluminum post with copper layer or copper post with aluminum layer) to combine the advantages of each material - aluminum for cost-effectiveness and copper for conductivity and weldability. The composite design allows optimization of both manufacturing ease and bonding strength through proper material selection and structural configuration
2Strength
If the second metal layer is extended to increase bonding area, then the bonding strength improves, but the device complexity increases
Solution Approach 1:
The second metal layer is extended not only in the axial direction but also wraps around the first metal post in the radial direction, utilizing multiple dimensions to increase bonding area. This multi-dimensional extension achieves greater bonding strength without proportionally increasing complexity, as the wrapping configuration is more efficient than adding multiple separate components
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
Enhances bonding strength and reduces the risk of detachment, ensuring improved overcurrent capacity and durability of the conductive structure.
Implementation Method 1
a second-metal layer bonded to a surface of the first-metal post, wherein the second-metal layer wraps the first end and extends toward the second end
Data Source
AI summary
A conductive structure and a manufacturing method, 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. 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 configured to connect to a tab. In the conductive structure, the metal layer bonded to the surface of the first end of the metal post is arranged to extend from the surface of the first end of the metal post to the second end. An end surface of the first end of the metal post and at least part of a surface of the metal post are covered by the metal layer.