Composite Battery Pole Locking Structure for Copper-Aluminum Reliability
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Solution Overview
Problem
The combination reliability between copper and aluminum parts in a composite pole is poor due to their different melting points and material fluidity, leading to poor reliability of the pole.
Innovation Solution
A pole design with a first metal part having an embedded groove and a second metal part with a connecting groove and embedding block, where the embedding block is embedded into the groove with limited depth and height dimensions, ensuring secure locking and strength between the metal parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a composite pole with copper and aluminum parts is adopted to improve conductivity and control weight, then the conductivity and weight are improved, but the combination reliability between copper and aluminum parts deteriorates due to different melting points and material fluidity
Solution Approach 1:
The connecting groove is divided into multiple sections with different embedding block configurations. The groove includes a first section with a first embedding block and a second section with a second embedding block, allowing different connection strategies for different material combinations (copper-aluminum or aluminum-copper), thereby improving combination reliability for each segment
Solution Approach 2:
The connecting groove is designed with non-uniform characteristics: the first section has a first embedding block with specific dimensions, while the second section has a second embedding block with different dimensions. This local differentiation allows optimization for specific material pairs, improving the connection strength and combination reliability at each local interface
2Reliability
If the embedding block is made larger to improve connection reliability, then the combination reliability is improved, but the structural integrity and tensile resistance of the pole deteriorate due to excessive material removal
Solution Approach 1:
Instead of using a single large embedding block that would compromise structural integrity, the design uses multiple smaller embedding blocks distributed along the connecting groove. Each embedding block provides partial connection reliability, while the cumulative effect achieves the required overall reliability without excessive material removal from any single location
Solution Approach 2:
The connection interface is segmented into multiple embedding blocks rather than one large block. This segmentation distributes the connection load across multiple points, maintaining both combination reliability and the structural integrity of the pole body by preserving more material in the groove walls
Data Source
AI summary
A pole, a cover plate assembly and a battery cell are provided. The pole includes a first metal part and a second metal part. The first metal part has an outer peripheral surface, and the outer peripheral surface is provided with an embedded groove. The second metal part is provided with a connecting groove, and one end of the first metal part is embedded into the connecting groove. An embedding block is provided protruding from a wall of the connecting groove toward the first metal part, and the embedding block is embedded into the embedded groove. A thickness of the wall of the connecting groove is D, and along a radial direction of the pole, a depth of the embedding block embedded into the embedded groove is L1, satisfying: 0<L1≤0.5D.