Future innovations in pole lugs and connectors
main content
In the microscopic world of the starting lithium battery of a motorcycle, the tabs and connectors are like the "highway toll stations" of electric current, undertaking the core mission of efficiently transmitting the current generated by the active substances inside the battery cell to the external circuit. These seemingly simple metal components need to maintain ultra-low impedance under instantaneous current impacts of over 300A, while ensuring structural stability under harsh working conditions such as vibration and alternating high and low temperatures. This article will analyze the technical mysteries of tabs and connectors from the perspective of material connection innovation.
Composite TAB structure
Aluminum-copper transition layer: A 0.1mm thick Al/Cu composite strip was prepared by explosive welding process, and the difference in the coefficient of thermal expansion was reduced from 11×10⁻⁶/K to 5×10⁻⁶/K.
Graphene reinforcement: Copper tabs with 0.5% graphene nanosheets added have a reduced resistivity of 1.55×10⁻⁸Ω·m and a 50% improvement in creep resistance.
Intelligent connectors
Self-sensing TAB: Embedded with FBG fiber Bragg grating sensor, it can monitor the temperature rise (accuracy ±0.5℃) and strain (±5με) at the connection in real time.
Shape memory alloy: The NiTi alloy tabs restore their preset shape at 150℃, compensating for the mechanical stress caused by the expansion of the battery cells.
Low-temperature welding technology
Nano-silver sintering: 20nm silver particles (melting point 230℃) are used to achieve a joint resistance of less than 0.5mΩ at 250℃/10MPa.
Ultrasonic-laser hybrid welding: By simultaneously applying ultrasonic and laser energy, the welding time of aluminum tabs has been reduced from 200ms to 50ms.
Conclusion
By optimizing material properties and welding processes, the current transmission efficiency, cycle life and safety of batteries can be significantly enhanced. In the future, with the further development of materials science and manufacturing technology, tabs and connectors will achieve greater breakthroughs in efficiency, safety and cost, providing a solid guarantee for the performance improvement of motorcycle starting lithium batteries.
START-STOP LITHIUM battery
Enov start-stop battery is designed to provide excellent performance for high-demand start-stop vaehicles. It adopts the third-generation intelligent lithium platform architecture to achieve technological breakthroughs in core indicators such as cycle life, environmental adaptability and energy density. Compared with the traditional lead-acid battery system, the energy efficiency is increased by 210%, the cycle life is extended by 8-10 times, and the monthly self-discharge rate is controlled within 3%. Enov's unique low-temperature battery technology makes a breakthrough in achieving stable output in the whole climate domain from -30℃ to 65℃, maintaining more than 90% of the effective capacity release under extremely cold conditions (-30℃), and maintaining 90% of the capacity in high temperature environments (65℃).
The start-stop battery series products cover the mainstream voltage platform of 12V/24V/48V, and support flexible configuration of LFP (lithium iron phosphate) and NCM (lithium nickel cobalt manganese oxide) dual-material system. All models adopt modular design to support customization of different model specifications. Enuo engineering and technical team to provide full cycle technical service support, if you need, please contact us.
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