Copper-Aluminum Battery Cover Terminal Sealing at the Composite Interface
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Solution Overview
Problem
The existing power battery covers face issues with poor sealing due to the placement of the copper-aluminum composite terminal, leading to electrolyte penetration and battery failure, while also being heavy and costly due to the use of pure copper material.
Innovation Solution
A power battery cover design incorporating a copper-aluminum composite terminal with a seal clamped between the terminal and the top cover, featuring a copper base body and aluminum base body connected via a composite connection surface, along with upper and lower plastic insulators, to ensure effective sealing and reduce weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a copper-aluminum composite terminal is used to reduce weight and cost, then the weight and material cost are reduced, but the sealing reliability deteriorates due to electrolyte penetration
Solution Approach 1:
The terminal is segmented into copper and aluminum base body parts with distinct functions. The copper part contacts the current collector internally while the aluminum part extends externally, with a sealed composite connection surface between them. This segmentation allows weight reduction through aluminum usage while maintaining sealing integrity through the dedicated copper-aluminum interface design.
Solution Approach 2:
The seal acts as an intermediary element clamped between the copper-aluminum composite terminal and the top cover. This seal mediates the connection interface, preventing electrolyte penetration while allowing the lightweight aluminum structure to be used. The seal ensures that the composite connection surface remains protected despite the material transition.
2Reliability
If pure copper material is used for the terminal to ensure electrical performance, then the electrical conductivity is maintained, but the weight and cost increase
Solution Approach 1:
Different materials are applied to different parts of the terminal based on local requirements. The copper base body part is positioned where high electrical conductivity is critical (contacting the current collector), while the aluminum base body part is used where structural extension is needed but conductivity requirements are lower. This local quality approach maintains electrical performance where needed while reducing overall weight.
Solution Approach 2:
The terminal uses a composite structure combining copper and aluminum base body parts. The copper-aluminum composite terminal leverages the high conductivity of copper for internal connections and the lightweight properties of aluminum for external structure, achieving a balance between electrical performance and weight reduction through material composition.
3Device complexity
If the seal is placed in the conventional position, then the structure is simple, but the sealing effect is poor allowing electrolyte penetration
Solution Approach 1:
The sealing function is extracted and dedicated to a specific seal component that is clamped between the copper-aluminum composite terminal and the top cover. This separation of sealing function from the terminal structure itself allows for optimized sealing performance. The seal is specifically positioned to protect the composite connection surface, ensuring reliable sealing without compromising structural simplicity.
Data Source
AI summary
The present application relates to the technical field of power batteries, and specifically discloses a power battery cover and a power battery. The power battery cover includes a copper-aluminum composite terminal, a top cover, a seal, an upper plastic insulator and a lower plastic insulator. The copper-aluminum composite terminal is disposed to pass through the top cover, the upper plastic insulator and the lower plastic insulator. The copper-aluminum composite terminal includes a copper base body part and an aluminum base body part connected to each other, and a composite connection surface is formed between the aluminum base body part and the copper base body part, and sealed and wrapped by the seal.