Copper-Aluminum Pole Post Cold Heading for Low-Waste Cell Assembly
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Solution Overview
Problem
The existing methods for producing pole posts in batteries, such as friction welding, result in significant waste of raw materials and increased production costs due to the cutting and processing of metal composite blanks, which also pose risks of fracture and reduced structural strength.
Innovation Solution
A pole post design utilizing a copper-aluminum composite plate formed through the cold heading process, where a metal base and metal post with different materials are coaxially connected, featuring a first groove on the metal post to reduce material waste and enhance bonding strength, thereby improving structural integrity and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If friction welding process is used to connect upper metal block and lower metal block, then the pole post can be formed with two different metals meeting dimensional requirements, but significant waste of raw metal materials occurs and production cost increases
Solution Approach 1:
The invention changes the manufacturing process parameters from friction welding with cutting to cold heading forming. The cold heading process directly forms the pole post from a metal composite blank without requiring cutting operations, thereby eliminating material waste while maintaining dimensional precision through controlled plastic deformation
Solution Approach 2:
The invention replaces the friction welding mechanical system with a cold heading forming system. Instead of joining two separate metal blocks through welding and subsequent cutting, the cold heading process directly shapes the metal composite blank into the final pole post geometry, eliminating both welding-related material loss and cutting waste
2Strength
If friction welding and cutting process is used to form metal composite blanks, then pole post with two different metals can be produced, but structural strength is reduced and fracture risk increases
Solution Approach 1:
The invention applies preliminary action by performing cold heading forming on the metal composite blank before any cutting or separation operations. The cold heading process pre-establishes the final geometry and strengthens the metal composite structure through plastic deformation, eliminating subsequent cutting operations that would create stress concentrations and fracture risks
Solution Approach 2:
The invention changes the processing parameters from high-temperature friction welding to cold heading at room temperature. This parameter change avoids thermal cycles that can create weak zones in the metal composite, while the cold plastic deformation uniformly distributes stress and enhances the structural integrity of the pole post
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 cold heading process efficiently produces pole posts with reduced material waste and lower production costs, while enhancing structural strength and reliability by firmly bonding the copper and aluminum layers, thus improving the overall performance and safety of the battery.
Implementation Method 1
A pole post design utilizing a copper-aluminum composite plate formed through the cold heading process
Implementation Method 2
The cold heading process efficiently produces pole posts with reduced material waste and lower production costs, while enhancing structural strength and reliability by firmly bonding the copper and aluminum layers
Data Source
AI summary
The disclosure provides a pole post, a top cap assembly, and a cell. The pole post includes a metal base and a metal post; the metal post is disposed on a top of the metal base; a material of the metal post is different from a material of the metal base; a bottom of the metal post is connected to a top of the metal base, and a surface of the metal post away from the metal base is provided with a first groove.