Composite Electrode Terminal Structure for Copper-Aluminum Battery Joints
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Solution Overview
Problem
The characteristics of conventional electrode terminals in batteries need enhancement.
Innovation Solution
The electrode terminal is composed of a first member made of copper or copper alloy, a second member made of copper alloy, and a third member made of aluminum or aluminum alloy, with the first and third members being adjacent but not in direct contact, and all members being bonded to a conductive member using laser bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode terminal uses a single material (e.g., copper or aluminum), then the manufacturing process is simple, but the electrical conductivity and structural strength cannot be simultaneously optimized
Solution Approach 1:
The electrode terminal employs a composite structure with a copper-based material (first material) providing high electrical conductivity and an aluminum-based material (second material) providing lightweight structural properties. This composite material approach allows simultaneous optimization of electrical conductivity and structural characteristics that cannot be achieved with a single material.
Solution Approach 2:
The electrode terminal is divided into multiple sections with different materials: a first section made of copper-based material and a second section made of aluminum-based material. This segmentation allows each section to be optimized for its specific function - the copper section for electrical conductivity and the aluminum section for structural support and weight reduction.
2Reliability
If different materials are used in the electrode terminal, then electrical conductivity and structural properties are improved, but bonding between different materials becomes difficult
Solution Approach 1:
A third material serving as an intermediary layer is provided between the copper-based first material and the aluminum-based second material. This intermediate layer facilitates bonding between the two dissimilar materials, enabling reliable joint formation while maintaining the benefits of the composite structure. The intermediary material acts as a bridge that compatible bonds with both copper and aluminum.
3Ease of manufacture
If the electrode terminal uses conventional bonding methods, then manufacturing is straightforward, but stress concentrations occur at material interfaces
Solution Approach 1:
The bonding process utilizes laser welding with controlled parameters (power, speed, focal position) to create strong joints between the different materials. By optimizing the laser welding parameters, the process achieves reliable bonding while minimizing heat-affected zones and preventing stress concentrations at the material interfaces. The third material's properties are also selected to match thermal and mechanical parameters that reduce stress during bonding.
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 enhances the performance and durability of the electrode terminal by ensuring electrical conductivity while maintaining structural integrity and reducing stress concentrations.
Implementation Method 1
all members being bonded to a conductive member using laser bonding
Data Source
AI summary
An electrode terminal (negative electrode terminal) includes a first member that is electrically connected with a charge/discharge body of a battery and that includes a first metal (copper or a copper alloy). The electrode terminal also features a second member that includes a first insertion section into which the first member is inserted. The second member is bonded with the first member and includes the first metal. The electrode terminal also features a third member that includes a second insertion section into which the first member is inserted. The third member is bonded with the second member and includes a second metal (aluminum or an aluminum alloy) which is a material different from the first metal. The third member is bonded with a conductive member (busbar) including the second metal, on a facing surface P facing the conductive member (busbar) that electrically connects a first battery and a second battery.