Battery Pole Assembly With Interlocking Flanges for Cu-Al Joints
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Solution Overview
Problem
The bonding force between copper and aluminum materials in battery poles is low, leading to easy separation and affecting electrical performance.
Innovation Solution
A pole structure with convex flanges and mating grooves, along with an insulating member and welding ring, enhances the bonding surface and stability between copper and aluminum components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stamping method is used to connect copper and aluminum materials, then the pole has better electrical performance, but the bonding force at the joint surface is low
Solution Approach 1:
The pole is divided into multiple sections with flanges and connecting grooves, allowing the copper and aluminum materials to be connected through a segmented structure rather than a simple stamping joint. This segmentation increases the bonding surface area and distributes the stress, thereby improving both the bonding force and electrical performance.
Solution Approach 2:
The connection structure extends from a two-dimensional stamping joint to a three-dimensional structure with flanges and connecting grooves. This dimensional change increases the bonding surface area and provides multiple contact points, significantly enhancing the bonding force between copper and aluminum materials while maintaining electrical performance.
2Device complexity
If stamping method is used to connect copper and aluminum materials, then the pole structure is simple, but the materials easily separate
Solution Approach 1:
The pole structure is segmented into multiple parts with flanges and connecting grooves, which prevents material separation by providing interlocking features. This segmentation maintains relative simplicity while significantly improving the stability of the material connection.
Solution Approach 2:
The flange structure is nested within the connecting groove, creating an interlocking arrangement that prevents separation. This nested design provides enhanced stability without significantly increasing the overall complexity of the pole structure.
3Strength
If flange and connecting groove structure is used, then the bonding force is improved, but the device complexity increases
Solution Approach 1:
The segmentation into flanges and connecting grooves provides a modular design that improves bonding force through increased surface area and interlocking features, while the modularity helps manage the overall complexity of the structure.
Data Source
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AI summary
A pole (11), a pole component (10), and a battery are provided. The pole (11) includes a first pole portion (111) and a second pole portion (112). An outer periphery of the first pole portion (111) is convexly provided with a first flange (1114). An end of the second pole portion (112) is provided with a mating groove (1121), and the first end (1111) is provided in the mating groove (1121) and engages with the second pole portion (112). An outer periphery of the second pole portion (112) is convexly provided with a second flange (1125), the second flange (1125) is provided with a first connecting groove (1126), and the first flange (1114) is at least partially located in the first connecting groove (1126) and engages with the second flange (1125). The pole improves a bonding force between the first pole portion and the second pole portion.