Battery Cover Lead-Out Structure for Reliable Copper-Aluminum Bonding
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Solution Overview
Problem
The reliability of the outer conductive member in batteries is poor due to the poor connection between copper and aluminum plates of different metals used in the electrode lead-out member.
Innovation Solution
A cover assembly with an outer conductive member comprising a first metal layer and a second metal layer of different materials, connected through a connection layer, ensuring a strong and reliable electrical connection, and optionally featuring through holes, sink portions, and accommodating grooves to enhance the connection and reduce material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper plate and aluminum plate are soldered together to form the outer conductive member, then the electrical connection between electrode tabs and external aluminum bar is achieved, but the connection reliability is poor due to dissimilar metal bonding
Solution Approach 1:
The patent introduces an intermediate metal layer between the copper plate and aluminum plate. This intermediate layer acts as a mediator that is compatible with both dissimilar metals, enabling reliable bonding. The intermediate layer resolves the incompatibility between copper and aluminum, allowing stable electrical connection without the reliability issues of direct dissimilar metal soldering.
Solution Approach 2:
The outer conductive member is constructed as a composite structure with multiple metal layers (copper plate, intermediate metal layer, and aluminum plate). This composite material approach combines the advantages of different metals while eliminating their direct incompatibility, achieving both good electrical conductivity and reliable mechanical connection.
2Reliability
If a connection layer is added between the first metal layer and second metal layer to improve connection strength, then the reliability of the outer conductive member is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into the intermediate metal layer: it serves as both a connection layer for bonding dissimilar metals and as part of the outer conductive member's structural integrity. By merging the connection function and structural function into a single integrated layer, the design avoids adding separate complex components while achieving improved reliability.
3Loss of substance
If the second metal layer is placed entirely within the first through hole to reduce material costs, then the material cost of the second metal layer is reduced, but the connection area between metal layers is reduced
Solution Approach 1:
The patent applies local quality by concentrating the second metal layer specifically within the first through hole area where it is most needed for connection, rather than distributing it uniformly. This localized placement optimizes material usage - the second metal layer provides maximum connection benefit where the through hole exists while minimizing overall material consumption in less critical areas.
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
The solution ensures a robust and reliable connection between the metal layers, improving the strength and reliability of the outer conductive member while reducing material costs and preventing overflow of the connection material.
Implementation Method 1
the connection layer is made of solder, and at least a portion of the first metal layer and at least a portion of the second metal layer are connected by soldering
Data Source
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AI summary
The disclosure provides a cover assembly (10000), a battery, and an electronic apparatus. The electronic apparatus includes the battery, and the battery includes the cover assembly (10000). The cover assembly (10000) includes a cover body (1) and an electrode lead-out member (2). The cover body (1) has a penetrating cover through hole. The electrode lead-out member (2) has an outer conductive member (21) and an inner conductive member (22). The outer conductive member (21) includes a first metal layer (211) and a second metal layer (212) of different materials, and a connection layer (3) is provided between the first metal layer (211) and the second metal layer (212), so that the strength of connection between the first metal layer (211) and the second metal layer (212) is ensured.