Anti-corrosion treatment of dissimilar metal interfaces
The interfaces of dissimilar metals commonly found in battery cells, such as the connection between aluminum and copper, are high-risk areas for electrochemical corrosion. To prevent this kind of corrosion, a layer of nickel or zinc is usually plated on these interfaces. The coating can effectively isolate the two metals and prevent electrochemical corrosion caused by potential difference. For instance, at the connection points of the busbar, nickel or zinc plating can significantly enhance the corrosion resistance of the connection and extend the service life of the battery cells.
Optimal design of the packaging structure
The design of the battery packaging structure is equally important for anti-corrosion. A common optimization method is to adopt a non-vertical design of the connection structure between the tabs and the housing. This design can reduce local stress during the packaging process and prevent shell damage caused by stress concentration. Meanwhile, by creating an anti-corrosion space between the tabs and the casing and filling it with inert gases (such as helium, neon, argon, etc.), the risk of electrolyte corrosion can be further reduced.
The application of anti-corrosion coatings
Anti-corrosion coating is another effective means of anti-corrosion. For instance, polyaniline/silicon strong powder composite coatings have been proven to have excellent anti-corrosion performance in harsh environments. This coating significantly reduces the corrosion rate by forming a protective film to prevent the metal from coming into contact with corrosive media. The electrochemical performance test shows that both the corrosion current and the corrosion potential have significantly decreased, demonstrating a good protective effect.