Overlay Clad Battery Terminal for Reliable Electrical Connectivity
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Solution Overview
Problem
The existing battery terminals with inlay clad materials face challenges in mass productivity due to the need for precise positioning of the Ni—Cu alloy layer, making it difficult to improve production efficiency and electrical connectivity between different metal materials.
Innovation Solution
The use of an overlay clad plate material with Al or Al alloy and Cu or Cu alloy layers, where one layer is partially removed to expose the other, allowing for easier bonding and reduced formation of fragile intermetallic compounds, enhancing electrical connectivity and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inlay clad material with Ni-Cu alloy layer embedded in groove is used, then electrical connectivity between different metal materials is improved, but manufacturing complexity and positioning precision requirements increase
Solution Approach 1:
The patent inverts the conventional inlay clad structure by using overlay clad material where the Ni-Cu alloy layer is placed on top of the Al layer rather than embedded within it. This reversal eliminates the need for grooves and precise positioning, allowing the softer Ni-Cu layer to be simply stacked and bonded onto the Al layer, thereby resolving the contradiction between connectivity reliability and manufacturing precision requirements
Solution Approach 2:
The patent employs composite clad material structure combining Al layer and Ni-Cu alloy layer with different physical properties. The Al layer provides good electrical conductivity and corrosion resistance, while the Ni-Cu alloy layer offers excellent weldability and strength. This composite structure enables both layers to contribute their advantageous properties, achieving reliable electrical connectivity without complex positioning requirements
2Reliability
If inlay clad material with groove structure is used, then electrical connectivity is improved, but mass productivity decreases due to complex preparation
Solution Approach 1:
By inverting the clad structure from inlay to overlay configuration, the patent eliminates the time-consuming groove formation process. The Ni-Cu alloy layer is simply placed on top of the Al layer and bonded, which can be done continuously in mass production, thereby significantly improving productivity while maintaining electrical connectivity through the layered composite structure
Solution Approach 2:
The patent changes the structural parameter of the clad material from an embedded groove configuration to a surface-overlay configuration. This parameter change simplifies the manufacturing process from multi-step precision machining to simple stacking and bonding, enabling continuous mass production while the layered structure continues to provide excellent electrical connectivity between Al and Cu components
3Productivity
If overlay clad plate material is used, then mass productivity is improved, but intermetallic compound formation may increase due to bonding process
Solution Approach 1:
The patent applies local quality control by selectively positioning the Ni-Cu alloy layer on specific areas of the Al layer where bonding is required. The overlay structure allows the Ni-Cu layer to be placed only in regions needing enhanced weldability and strength, while other areas maintain the Al layer's properties. This localized approach enables mass production through simple stacking while controlling intermetallic compound formation only where necessary, preserving overall bonding strength
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 approach simplifies the preparation of battery terminals, improves mass productivity, and reduces the formation of fragile intermetallic compounds, leading to stronger bonds and efficient electrical connections between different metal materials.
Implementation Method 1
an overlay clad plate material including at least a first metal layer made of Al or Al alloy and a second metal layer made of Cu or Cu alloy, formed by bonding at least the first metal layer and the second metal layer to each other in the thickness direction
Data Source
AI summary
A battery terminal includes an overlay clad plate material including at least a first metal layer made of Al or Al alloy and a second metal layer made of Cu or Cu alloy, formed by bonding at least the first metal layer and the second metal layer to each other in the thickness direction. Either the first metal layer or the second metal layer of the clad plate material is partially removed to form an exposure surface on which either the second metal layer or the first metal layer is exposed in the clad plate material.