Yongtong New Material Building the Future Together
Battery terminal
The advantages of copper-aluminum composite materials in the lithium battery terminal industry primarily lie in their superior interfacial bonding performance, enhanced electrical and thermal conductivity, lightweight design, cost-effective manufacturing processes, and robust structural reliability. Here’s a detailed analysis:
1. High metallurgical bonding strength effectively addresses interface delamination issues.
Traditional copper-aluminum composite terminals typically rely on friction welding, a process that often leads to thermal stress-induced cracks at the interface, resulting in low peel strength (around 40 N/mm). In contrast, the cast-rolling method produces copper-aluminum composites by directly melting aluminum and solid copper together, followed by continuous rolling to achieve seamless metallurgical bonding. This results in an interfacial bond strength exceeding 70 N/mm—significantly higher than that achieved through friction welding—and effectively prevents battery failure caused by interfacial delamination during riveting or normal use.
2. Excellent electrical conductivity, nearly matching that of pure copper
The electrical conductivity of copper-aluminum composite materials can reach over 98% of the theoretical value for parallel connections of copper and aluminum (e.g., in the T21060 series), delivering conductive performance nearly equivalent to pure copper. Meanwhile, the extensive use of aluminum layers—such as an aluminum content as high as 70%—significantly reduces material costs, striking a balance between electrical efficiency and affordability.
3. Lightweight design, aligning with the trend in power batteries
Aluminum has a density that is only one-third that of copper. In copper-aluminum composite materials, the aluminum layer accounts for a high proportion—up to 70%, for instance—resulting in an overall weight that’s more than 50% lighter than pure copper terminals. This significant reduction in weight effectively lowers the total mass of power batteries, perfectly aligning with the lightweighting demands of next-generation electric vehicles.
4. Enhanced corrosion resistance for extended service life
The metallurgical bonding at the composite interface eliminates residual oxide films typical of conventional friction welding, while the aluminum surface readily forms a dense oxide layer (thickness ≥ 5 μm), significantly enhancing its resistance to electrochemical corrosion. This, in turn, reduces issues such as increased resistance or fracture in the terminal posts caused by corrosion, ultimately extending the service life of the terminals.
5. Process innovation reduces costs and boosts production efficiency
The casting and rolling process enables continuous production (with a single machine capable of processing approximately 7,000 terminals per hour), representing more than a 10-fold increase in productivity compared to traditional friction welding (30 terminals per hour). At the same time, material utilization improves by 30%, while overall costs are reduced by 25% to 40%, significantly lowering the manufacturing cost of the terminals.
Copper-aluminum composite materials, with their metallurgical bonding interface, exceptional electrical conductivity, lightweight design, cost-effective manufacturing processes, and reliable structural integrity, have emerged as the ideal material for lithium-battery terminals—particularly well-suited for high-demand applications like new-energy vehicles, where lightweight construction and reliability are critical. Currently, this material has been successfully integrated into the terminal components of power batteries produced by leading companies such as CATL and BYD, driving significant technological advancements across the industry.
Battery terminal 01
Battery terminal 02
Battery terminal 03
Battery terminal 04
Mobile phone/WeChat:
Leave a Message
Leave a message online to obtain a free product quotation
Copyright © Henan Yongtong Composite New Material Technology Co., Ltd.
Powered by www.300.cn Supports IPV6 Privacy Agreement