Clad structure and terminal component for battery

Abstract

To provide a clad structure with which productivity in finished products is good; a junction strength of an aluminum material and a copper material is easily secured; and long-term reliability can be expected even in a battery application for an automobile, etc., and a terminal component for a battery.SOLUTION: A clad structure comprises: a basis part; a wall part extending upward from an outer edge of an upper bottom face of the basis part; a flange part extending from an end of the wall part in a radiation direction orthogonally to the wall part; a leg part extending downward from an outer edge of a lower bottom face of the basis part; a first recessed part which is defined by the upper bottom face of the basis part and an inner wall face of the wall part; and a second recessed part which is defined by the lower bottom face of the basis part and an inner leg face of the leg part. A first surface expanded from the upper bottom face of the basis part through the inner wall face of the wall part to an upper flange face of the flange part consists of an aluminum material, and a second surface expanded from the lower bottom face of the basis part through the inner leg face, a lower leg face and an outer leg face of the leg part and an outer wall part of the wall part to a lower flange face of the flange part consists of a copper material. A terminal component for a battery uses the clad structure.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a clad structure and a battery terminal part, and more particularly to a clad structure and a battery terminal part suitable for a negative electrode terminal electrically connected to the negative electrode side of a lithium ion secondary battery or the like. [Background technology]

[0002] BACKGROUND ART Conventionally, a negative electrode terminal (terminal component) for a battery that is formed by ultrasonically joining two components is known (see Patent Documents 1 and 2).

[0003] Patent Document 1 discloses a battery negative electrode terminal (terminal component) that is formed by ultrasonically joining a plate-shaped component made of aluminum and a shaft-shaped component made of copper (see Figure 4, etc.). In the case of this terminal component, an ultrasonic horn is brought into contact with the upper surface of the plate-shaped component, and ultrasonic joining is performed between the center of the lower surface of the plate-shaped component and the upper end surface of the shaft-shaped component.

[0004] Patent Document 2 discloses a battery negative electrode terminal (terminal component) formed by ultrasonically welding a plate-shaped component made of aluminum and a shaft-shaped component made of copper (see Figure 5, etc.). This shaft-shaped component has a recess located at the center of one end of the shaft and a flange whose upper surface extends radially from the end of the shaft and faces the lower surface of the plate-shaped component. In the case of this terminal component, an ultrasonic horn is pressed into the recess of the shaft-shaped component while being brought into contact with the upper surface of the plate-shaped component. This ultrasonically bonds the lower surface of the plate-shaped component and the flange of the shaft-shaped component, and also plastically deforms the center of the plate-shaped component into the recess of the shaft-shaped component, thereby crimping the plate-shaped component to the shaft-shaped component.

[0005] The terminal component disclosed in Patent Document 1 carries the risk of losing the bond strength between the aluminum plate-shaped component and the copper shaft-shaped component when the battery equipped with the component is used in an application where it is subjected to intermittent and long-term vibrations, such as in an automobile. On the other hand, the terminal component disclosed in Patent Document 2 uses a combination of ultrasonic bonding and crimping bonding to ensure sufficient bond strength between the aluminum plate-shaped component and the copper shaft-shaped component, so that long-term stability can be expected even in the above-mentioned application, such as in an automobile. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 7334215 [Patent Document 2] Patent No. 7389766 Summary of the Invention [Problem to be solved by the invention]

[0007] The terminal components disclosed in Patent Documents 1 and 2 require separate preparation of a plate-shaped component made of aluminum and a shaft-shaped component made of copper. Furthermore, the terminal component disclosed in Patent Document 2 is manufactured using a combination of ultrasonic bonding, in which the plate-shaped component is softened and fluidized by ultrasonic vibrations and filled into the recess of the shaft-shaped component, and crimping. Therefore, a method is required to ensure that the fluidized plate-shaped component does not obstruct the filling of the recess of the shaft-shaped component. For example, the shaft-shaped component may be provided with a through-hole (leak hole) to allow gas (air in the case of ultrasonic bonding in an atmospheric environment) in the recess to escape. In this case, the shape of the shaft-shaped component with the recess becomes complex, which particularly affects the productivity of the shaft-shaped component (material yield, processing time, processing cost, etc.), potentially compromising the productivity of the terminal component.

[0008] One object of the present invention is to provide a clad structure and a battery terminal component that have good productivity as a finished product, that can easily ensure the bonding strength between an aluminum material and a copper material, and that can be expected to have long-term reliability even when used in batteries for automobiles, etc. [Means for solving the problem]

[0009] The cladding structure according to the present invention comprises a base portion having an upper bottom surface and a lower bottom surface, a wall portion having an inner wall surface and an outer wall surface extending upward from the outer edge of the upper bottom surface, upper and lower flange surfaces extending in a radial direction perpendicular to the wall portion from the end of the upwardly extending wall portion, a flange portion having an outer flange surface at the end extending in the radial direction, inner and outer leg surfaces extending downward from the outer edge of the lower bottom surface, and a lower leg surface at the end extending downward. The base has a leg portion, a first recess defined by the upper bottom surface and the inner wall surface, and a second recess defined by the lower bottom surface and the inner leg surface, and the first surface extending from the upper bottom surface, via the inner wall surface, to the upper flange surface is made of aluminum material, and the second surface extending from the lower bottom surface, via the inner leg surface, the lower leg surface, the outer leg surface, and the outer wall portion, to the lower flange surface is made of copper material.

[0010] In the cladding structure of the present invention, the inner wall surface of the wall portion preferably comprises a vertical wall surface extending upward from the upper bottom surface of the base portion and an inclined wall surface connecting from the vertical wall surface to the upper flange surface of the flange portion.

[0011] In the cladding structure according to the present invention, preferably, the outer flange surface of the flange portion has a boundary between the first surface continuing from the upper flange surface and the second surface continuing from the lower flange surface.

[0012] The clad structure having the above-mentioned configuration is suitable for use as a battery terminal part.

[0013] The battery terminal part according to the present invention comprises a base portion having an upper bottom surface and a lower bottom surface, a wall portion having inner and outer wall surfaces extending upward from the outer edge of the upper bottom surface, upper and lower flange surfaces extending radially from the end of the upwardly extending wall portion perpendicular to the wall portion, a flange portion having an outer flange surface at the end extending radially, a leg portion having inner and outer leg surfaces extending downward from the outer edge of the lower bottom surface and a lower leg surface at the end extending downward, and The clad structure has a first recess defined by a bottom surface and the inner wall surface, and a second recess defined by the lower bottom surface and the inner leg surface, and the first surface extending from the upper bottom surface, through the inner wall surface, to the upper flange surface is made of aluminum material, and the second surface extending from the lower bottom surface, through the inner leg surface, the lower leg surface, the outer leg surface, and the outer wall portion, to the lower flange surface is made of copper material.

[0014] In the battery terminal part of the present invention, preferably, the inner wall surface of the wall portion is composed of a vertical wall surface extending upward from the upper bottom surface of the base portion and an inclined wall surface connecting from the vertical wall surface to the upper flange surface of the flange portion.

[0015] In the battery terminal part according to the present invention, preferably, the outer flange surface of the flange portion has a boundary between the first surface continuing from the upper flange surface and the second surface continuing from the lower flange surface. [Effects of the Invention]

[0016] According to the present invention, it is possible to provide a clad structure and a battery terminal component that have good productivity as a finished product, that can easily ensure the bonding strength between the aluminum material and the copper material, and that can be expected to have long-term reliability even when used in batteries for automobiles, etc. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a diagram showing an example of an embodiment of a cladding structure according to the present invention; [Figure 2] FIG. 2 is a flow chart showing an example of a method for manufacturing a cladding structure according to the present invention. [Figure 3]FIG. 10 is a diagram showing an example of a clad piece prepared in a material preparation step. [Figure 4] FIG. 3 is a diagram showing an example of a first molded body molded in a first molding step. [Figure 5] FIG. 4 is a diagram showing an example of a second molded body molded in a second molding step. [Figure 6] FIG. 10 is a diagram showing an example of a third molded body molded in a third molding step. [Figure 7] FIG. 1 is a diagram showing an example of a negative electrode side terminal connection structure in which a clad structure is used as a battery terminal component to electrically connect a negative electrode side component of one battery to a connection component connected to another battery. [Figure 8] 8 is a diagram showing an example of a terminal connection structure in which the negative electrode side component of the battery is different from that illustrated in FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0018] The cladding structure according to the present invention will be described below by taking an example of a configuration that is considered to be preferable as an embodiment, with reference to the drawings as needed.

[0019] 1 shows the configuration of one example of an embodiment of a clad structure 1 according to the present invention. The clad structure 1 is particularly suitable for battery components that require weight reduction while maintaining electrical properties, and is suitable, for example, for a terminal component (battery terminal component 1) for electrically connecting a negative electrode component of a battery to a connecting component (bus bar) between the batteries.

[0020] As shown in Fig. 1, the clad structure 1 (battery terminal component 1) includes a base portion 10, a wall portion 11, a flange portion 12, a leg portion 13, a first recess 14, and a second recess 15. The clad structure 1 (battery terminal component 1) is a molded body obtained by plastically deforming a clad plate according to its respective portions. A method for manufacturing a molded body by plastically deforming a clad plate according to its respective portions will be described later.

[0021] The base 10 has an upper surface 10A and a lower surface 10B. The base 10 is composed of an upper (Z1 side) aluminum layer 16 and a lower (Z2 side) copper layer 17. Therefore, the upper surface 10A is the surface of the aluminum layer 16, and the lower surface 10B is the surface of the copper layer 17. The aluminum layer 16 and the copper layer 17 that make up the base 10 are pressure-welded in their thickness direction (Z direction), and are thermally diffusion bonded at the pressure-welded interface, after which they are plastically deformed accordingly. Note that when the legs 13 are formed from the original shape of the base 10, the copper layer 17 of the original shape of the base 10 is significantly plastically deformed.

[0022] The base 10 does not need to have a through hole connecting the first recess 14 and the second recess 15 in the Z direction. Because the base 10 does not have a through hole in the Z direction, even if the electrolyte leaks from inside the battery to the terminal connection part on the negative electrode side, the electrolyte can be blocked within the second recess 15. This prevents the electrolyte from leaking outside the battery through the terminal connection part on the negative electrode side.

[0023] The upper surface 10A of the base portion 10 is included in the surface that constitutes the first surface made of aluminum material, and can be made of approximately the same aluminum material (aluminum layer 16) as the connection component 3 (see FIGS. 7 and 8) that is also made of aluminum material. Therefore, because the upper surface 10A of the base portion 10 is made of approximately the same aluminum material as the connection component 3, even when a terminal connection structure 3 (not shown) is adopted in which the upper surface 10A contacts the connection component, an increase in electrical resistance at the contact interface between the upper surface 10A and the connection component 3 is suppressed, and good conductivity between the base portion 10 and the connection component 3 can be ensured.

[0024] Furthermore, the lower bottom surface 10B of the base portion 10 is included in the surface constituting the second surface made of copper material, and can be made of substantially the same copper material (copper layer 17) as the negative electrode side component 2 (see FIGS. 7 and 8) made of copper material. Therefore, since the lower bottom surface 10B of the base portion 10 is made of substantially the same copper material as the negative electrode side component 2, even when a terminal connection structure (see FIG. 7) in which the lower bottom surface 10B and the negative electrode side component 2 contact each other is adopted, an increase in electrical resistance at the contact interface between the lower bottom surface 10B and the negative electrode side component 2 is suppressed, and good conductivity can be ensured between the base portion 10 and the negative electrode side component 2.

[0025] The wall 11 has an inner wall surface 11A and an outer wall surface 11B extending upward (toward the Z1 side) from the outer edge of the upper bottom surface 10A. The wall 11 is composed of an aluminum layer 16 on the inner wall surface 11A side and a copper layer 17 on the outer wall surface 11B side. Therefore, the inner wall surface 11A is the surface of the aluminum layer 16, and the outer wall surface 11B is the surface of the copper layer 17. The aluminum layer 16 and the copper layer 17 that make up the wall 11 are pressure-welded in their thickness direction (X direction), and are thermally diffusion-bonded at the pressure-welded interface, after which they are plastically deformed accordingly.

[0026] Inner wall surface 11A of wall portion 11 is included in the surface that constitutes the first surface made of aluminum material, and can be made of approximately the same aluminum material (aluminum layer 16) as connection part 3 (see FIGS. 7 and 8) that is also made of aluminum material. Therefore, even when a terminal connection structure (not shown) is adopted in which inner wall surface 11A of wall portion 11 contacts connection part 3, an increase in electrical resistance at the contact interface between them is suppressed, and good conductivity can be ensured between wall portion 11 and connection part 3.

[0027] Furthermore, the outer wall surface 11B of the wall 11 is included in the surface that constitutes the second surface made of copper, and can be made of substantially the same copper material (copper layer 17) as the negative electrode side component 2 (see FIGS. 7 and 8) made of copper. Therefore, even when a terminal connection structure (see FIG. 8) is adopted in which the outer wall surface 11B of the wall 11 is in contact with the negative electrode side component 2, an increase in electrical resistance at the contact interface between them is suppressed, and good conductivity can be ensured between the wall 11 and the connection component 3.

[0028] The flange portion 12 has an upper flange surface 12A and a lower flange surface 12B that extend radially (in the X direction) from the end (Z1 side) of the wall portion 11, which extends upward (toward the Z1 side). The flange portion 12 further has an outer flange surface 12C at the end extending in the radial direction (in the X direction). The flange portion 12 is composed of an aluminum layer 16 on the upper side (Z1 side) and a copper layer 17 on the lower side (Z2 side). Therefore, the upper flange surface 12A is the surface of the aluminum layer 16, and the lower flange surface 12B is the surface of the copper layer 17. Furthermore, the outer flange surface 12C is formed by the surface of the aluminum layer 16 continuing from the upper flange surface 12A, and the surface of the copper layer 17 continuing from the lower flange surface 12B. Therefore, outer flange surface 12C has a boundary between aluminum layer 16 and copper layer 17. Aluminum layer 16 and copper layer 17 constituting flange 12 are pressure-welded in their thickness direction (Z direction), and are thermally diffusion bonded at the pressure-welded interface, after which they are plastically deformed accordingly.

[0029] Upper flange surface 12A of flange portion 12 is included in the surface that constitutes the first surface made of aluminum material, and can be made of approximately the same aluminum material (aluminum layer 16) as connecting part 3 (see FIGS. 7 and 8) that is also made of aluminum material. Therefore, even when a terminal connection structure (see FIGS. 7 and 8) is adopted in which upper flange surface 12A and connecting part 3 come into contact with each other, because upper flange surface 12A of flange portion 12 is made of approximately the same aluminum material as connecting part 3, an increase in electrical resistance at the contact interface between them is suppressed, and good conductivity can be ensured between flange 12 and connecting part 3.

[0030] Furthermore, the lower flange surface 12B of the flange portion 12 is included in the surface that constitutes the second surface made of copper, and can be made of substantially the same copper material (copper layer 17) as the negative electrode side component 2 (see FIGS. 7 and 8) made of copper. Therefore, even when a terminal connection structure is adopted in which the lower flange surface 12B and the negative electrode side component 2 come into contact with each other (such as a structure that does not use the seal 4 shown in FIG. 8), the lower flange surface 12B of the flange portion 12 is made of substantially the same copper material as the negative electrode side component 2, and therefore an increase in electrical resistance at the contact interface between them is suppressed, and good conductivity can be ensured between the flange portion 12 and the connection component 3.

[0031] The leg portion 13 has an inner leg surface 13A and an outer leg surface 13B extending downward (toward Z2) from the outer edge of the lower base surface 10B. The leg portion 13 further has a lower leg surface 13C at the end extending downward (toward Z2). The inner leg surface 13A, the outer leg surface 13B, and the lower leg surface 13C of the leg portion 13 are all formed by the copper layer 17. That is, the leg portion 13 is formed by the copper layer 17. Therefore, the inner leg surface 13A, the outer leg surface 13B, and the lower leg surface 13C are the surfaces of the copper layer 17. The copper layer 17 forming the leg portion 13 is significantly plastically deformed when it is formed from the original shape of the base portion 10 after being affected by the heating during the above-mentioned thermal diffusion bonding.

[0032] The inner wall surface 13A, the outer wall surface 13B, and the lower leg surface 13C of the leg 13 are included in the surface that constitutes the second surface made of copper, and can be made of substantially the same copper material (copper layer 17) as the negative-electrode-side component 2 (see FIGS. 7 and 8) made of copper. Therefore, even when a terminal connection structure (see FIG. 8) is adopted in which one or more of the inner wall surface 13A, the outer wall surface 13B, and the lower leg surface 13C contact the negative-electrode-side component 2, an increase in electrical resistance at the contact interface between the two is suppressed, and good conductivity can be ensured between the leg 13 and the connection component 3.

[0033] The first recess 14 is defined by an upper bottom surface 10A of the base 10 and an inner wall surface 11A of the wall 11. This first recess 14 can be used to electrically connect the clad structure 1 (battery terminal component 1) to a connection component 3 (see FIGS. 7 and 8) that is electrically connected to another battery. For example, a fitting structure (not shown) that inserts and fits the connection component 3 into this first recess 14 can easily and stably electrically connect the clad structure 1 (battery terminal component 1) to the connection component 3.

[0034] As described above, the upper bottom surface 10A of the base portion 10 and the inner wall surface 11A of the wall portion 11, which define the first recess 14, are the surfaces of the aluminum layer 16. Therefore, the surface of the first recess 14 is the surface of the aluminum layer 16. Furthermore, the surface of the first recess 14 is included in the surface that constitutes the first surface made of aluminum material, and can be made of approximately the same aluminum material (aluminum layer 16) as the connection part 3 (see FIGS. 7 and 8) made of aluminum material. Because the surface of the first recess 14 is the surface of the aluminum layer 16, even when a terminal connection structure (not shown) in which the first recess 14 and the connection part 3 contact each other is adopted, an increase in electrical resistance at the contact interface between them is suppressed, and good conductivity can be ensured between the flange 12 and the connection part 3.

[0035] The second recess 15 is defined by the lower bottom surface 10B of the base 10 and the inner leg surface 13A of the leg 13. This second recess 15 can be used to electrically connect the clad structure 1 (battery terminal component 1) and the negative electrode side component 2 of the battery (see FIGS. 7 and 8). For example, a fitting structure (see FIG. 7) in which the negative electrode side component 2 is inserted and fitted into this second recess 14 can easily and stably electrically connect the clad structure 1 (battery terminal component 1) and the negative electrode side component 2.

[0036] As described above, the lower bottom surface 10B of the base portion 10 and the leg wall surface 13A of the leg portion 13, which define the second recess 15, are the surfaces of the copper layer 17. Therefore, the surface of the second recess 15 is the surface of the copper layer 17. Furthermore, the surface of the second recess 15 is included in the surface that constitutes the second surface made of copper material, and can be made of substantially the same copper material (copper layer 17) as the negative electrode side component 2 (see FIGS. 7 and 8) made of copper material. Because the surface of the second recess 15 is the surface of the copper layer 17, even when a terminal connection structure (see FIG. 7) in which the second recess 15 and the negative electrode side component 2 contact each other is adopted, an increase in electrical resistance at the contact interface between them is suppressed, thereby ensuring good conductivity between the second recess 15 and the negative electrode side component 2.

[0037] As described above, the clad structure 1 (battery terminal component 1) has a surface region of the aluminum layer 16 that extends from the upper bottom surface 10A of the base portion 10, through the inner wall surface 11A of the wall portion 11, to the upper flange surface 12A of the flange portion 12. This surface region of the aluminum layer 16 is referred to as the first surface. As shown in FIG. 1 , this first surface occupies most of the surface of the aluminum layer 16.

[0038] As described above, the clad structure 1 (battery terminal component 1) has a surface region of the copper layer 17 that extends from the lower bottom surface 10B of the base portion 10, through the inner leg surface 13A, the lower leg surface 13C, the outer leg surface 13B, and the outer wall surface 11B of the wall portion 11, to the lower flange surface 12C of the flange portion 12. This surface region of the copper layer 17 is referred to as the second surface. As shown in FIG. 1 , this second surface occupies most of the surface of the copper layer 17.

[0039] The aluminum layer 16 located on the upper side (Z1 side) of the clad structure 1 (battery terminal component 1) is made of an aluminum material. This aluminum material may be a JIS A1000 series aluminum material (e.g., A1050, A1100, etc.) with good formability and weldability, or a material with a similar composition (pure aluminum). This aluminum material may also be a JIS A3000 series aluminum material (e.g., A3003, A3004, etc.) with higher hardness than the A1000 series aluminum material, or an even higher strength A5000 series aluminum material (e.g., A5052, A5083, etc.), or a material with a similar composition (aluminum alloy). For example, when high electrical conductivity is important, pure aluminum is preferably selected. When tensile strength and yield strength are important, an aluminum alloy is preferably selected.

[0040] The copper layer 17 located on the lower side (Z2 side) of the clad structure 1 (battery terminal component 1) is made of a copper material. This copper material may be a JIS C1000 series (C1020, C1100, etc.) copper alloy with excellent ductility and drawing workability, or a material with a similar composition (pure copper). This copper material may also be a JIS C2000 series (C2600, C2680, etc.) copper alloy with excellent ductility and drawing workability, a JIS C7000 series (A7250, etc.) copper alloy with a similar composition (copper alloy). For example, when high electrical conductivity is important, pure copper is preferably selected. When tensile strength and yield strength are important, a copper alloy is preferably selected.

[0041] Next, a manufacturing method of the clad structure 1 shown in Fig. 1 will be described with reference to a preferred manufacturing process diagram (flow chart) and appropriate drawings. Note that a battery terminal component constructed using the clad structure 1 may be constructed using the clad structure 1 as is, as in the above-described battery terminal component 1, or may be constructed by performing minor processing on the clad structure 1, so this can be handled as needed.

[0042] 2 shows a manufacturing process diagram (flow chart) of the clad structure 1 (battery terminal component 1). This manufacturing process includes, as main steps, a material preparation step, a first molding step, a second molding step, and a third molding step, and also includes, as an optional step, a fourth molding step, as needed.

[0043] <Material preparation process> The material preparation step is a step of preparing a clad piece 100 as shown in FIG. 3 using a clad plate as a material, as shown in FIG. 2. The clad piece 100, which serves as the starting material for forming the clad structure 1, is a small piece of clad plate with a two-layer structure composed of an aluminum layer 116 and a copper layer 117. The clad piece 100 can be formed by processing means such as punching or wire cutting using a clad plate having substantially the same layer structure as the clad piece 100. The aluminum layer 116 and copper layer 117 of the clad structure 1 (battery terminal component 1) that will be the finished product of the clad piece 100 can be designed taking into account the shape and volume of the aluminum layer 16 and copper layer 17 of the clad structure 1 (battery terminal component 1).

[0044] The clad plate (not shown) that is the material for the clad piece 100 is made by laminating and pressing (clad rolling) an appropriately tempered aluminum plate and a copper plate in the thickness direction (Z direction) and then subjecting the pressed-welded interface to an appropriate thermal diffusion reaction. The aluminum plate that constitutes the clad plate is the material that constitutes the aluminum layer 16 of the clad structure 1 (battery terminal component 1). The copper plate that constitutes the clad plate is the material that constitutes the copper layer 17 of the clad structure 1 (battery terminal component 1).

[0045] <1st molding process> The first molding step is a step of forming a first molded body 200 as shown in FIG. 4 using a clad piece 100 as shown in FIG. 2. In the first molding step, a general press molding method is used to mainly mold a base portion 210, a wall portion 211, and a flange portion 212, which are the original shapes of the base portion 10, the wall portion 11, and the flange portion 12 shown in FIG. 1. During this process, the clad piece 100 is plastically deformed to correspond to the shapes of each portion of the first molded body 200, which is the target shape. As a result, the first molded body 200 includes the base portion 210, the wall portion 211, the flange portion 212, and a first recess 214, as shown in FIG. 4. The base portion 210, the wall portion 211, the flange portion 212, and the first recess 214 of the first molded body 200 correspond to the base portion 10, the wall portion 11, the flange portion 12, and the first recess 14 of the clad structure 1. In this first compact 200, the aluminum layer 216 located on the upper side (Z1 side) extends inside the first recess 214, and the copper layer 217 located on the lower side (Z2 side) extends outside the first recess 214.

[0046] <Second molding process> The second forming step is a step of forming a second formed body 300 as shown in FIG. 5 using a first formed body 200 as shown in FIG. 2. In the second forming step, a general press forming method is used to form mainly wall portions 311 and flange portions 312, which are the original shapes of the wall portions 11 and flange portions 12 shown in FIG. 1, and also to form a base portion 310, in which the thickness (length in the Z direction) of the copper layer 317 is large. The large thickness of the copper layer 317 that constitutes the base portion 310 ensures that there is copper material (copper layer 17) for forming the leg portions 13 shown in FIG. 1. During this process, the first formed body 200 is plastically deformed to correspond to the shapes of each portion of the second formed body 300, which is the target shape. 5, the second compact 300 includes a base portion 210, a wall portion 211, a flange portion 212, and a first recess 214, which are the original shapes of the base portion 10, the wall portion 11, the flange portion 12, and the first recess 14 of the cladding structure 1. The second compact 300 also includes the base portion 310 having a thick copper layer 317 necessary for forming the leg portion 13 and the second recess 15 of the cladding structure 1 in the next step. In the second compact 300, the aluminum layer 316 located on the upper side (Z1 side) extends inside the first recess 314, and the copper layer 317 located on the lower side (Z2 side) extends outside the first recess 314.

[0047] <Third molding process> The third molding step is a step of forming a third molded body 400 as shown in FIG. 6 using a second molded body 300, as shown in FIG. 2. In the third molding step, a general press molding method is used to plastically deform the base 310 and wall 311 of the second molded body 300 to form a base 410, leg 413, and second recess 415, which correspond to the base 10, leg 13, and second recess 15 shown in FIG. 1. During this process, the second molded body 300 is plastically deformed to correspond to the shapes of each portion of the third molded body 400, which is the target shape. This completes the base 410, wall 411, flange 412, and leg 413, which substantially correspond to the base 10, wall 11, flange 12, and leg 13 shown in FIG. 1. Furthermore, a first recess 414 and a second recess 415, which substantially correspond to the first recess 14 and the second recess 15, are defined. Also, a first surface and a second surface of the third molded body 400 that substantially correspond to the first surface and the second surface of the clad structure 1 (battery terminal component 1) are obtained.

[0048] The third molded body 400 can have a shape substantially identical to the base 10, wall 11, flange 12, leg 13, first recess 14, and second recess 15 of the clad structure 1. As shown in FIG. 6 , the third molded body 400 includes a base 410, wall 411, flange 412, leg 413, first recess 414, and second recess 415. In the third molded body 400, the aluminum layer 416 located on the upper side (Z1 side) extends inside the first recess 414, and the copper layer 417 located on the lower side (Z2 side) extends outside the first recess 414. As a result, the first surface of the third molded body 400 where the aluminum layer 416 is exposed and the second surface of the third molded body 400 where the copper layer 417 is exposed correspond to the first surface and second surface of the clad structure 1 (battery terminal component 1).

[0049] As a result, the third molded body 400 becomes a finished product if it passes a predetermined inspection after, for example, surface cleaning to remove contaminants (metal powder, dirty oil, dust, etc. resulting from molding). This finished product is the clad structure 1 (battery terminal component 1). Note that, for example, if the flange portion 412 of the third molded body 400 is long in the X direction (has excess thickness), a fourth molding step shown in FIG. 2 can be added.

[0050] <4th molding process> In the fourth molding step, when the flange 412 of the third molded body 400 is long in the X direction (has excess thickness), the outer flange surface 412C is partially removed by a general press molding method (trimming molding method) to mold it into a predetermined shape. In the fourth molding step, the outer flange surface 412C of the flange 412 of the third molded body 400 is trimmed to obtain a shape similar to the outer flange surface 12C of the flange 12 of the cladding structure 1. The fourth molded body (not shown) obtained in the fourth molding step is then subjected to the surface cleaning and inspection described above to become a finished product. This finished product is the battery terminal component 1.

[0051] As described above, the clad structure 1 (battery terminal component 1) according to the present invention can be manufactured by a simple press-forming method shown in the manufacturing process diagram (flow chart) of FIG. 2 . In the manufacturing process shown in FIG. 2 , the clad structure 1 (battery terminal component 1) can be obtained starting from a clad piece 100 made of a two-layer clad plate having an aluminum layer and a copper layer. The clad plate from which the clad piece 100 is made can be easily manufactured by a typical clad plate manufacturing method involving rolling dissimilar metals (clad rolling) and diffusion annealing. A clad plate that has undergone appropriate rolling (clad rolling) and diffusion annealing has an aluminum layer and a copper layer properly thermally diffusion bonded, providing sufficient bonding strength to prevent delamination between the layers. Therefore, when the clad plate is used to form the clad piece 100, the aluminum layer 116 and the copper layer 117 of the clad piece 100 do not easily delaminate. By using the clad piece 100 made from this clad plate as the starting material, the clad piece 100 can adequately withstand the plastic deformation described above, and the aluminum layer 16 and copper layer 17 that make up the clad structure 1 (battery terminal component 1) do not easily peel off.

[0052] Therefore, the clad structure 1 according to the present invention can use the clad piece 100 made from a clad plate as a starting material. From this perspective, productivity as a finished product can be expected, and it is easy to ensure the bonding strength between the aluminum material (aluminum layer 16) and the copper material (copper layer 17). As a result, the battery terminal component 1 constructed using the clad structure 1 can be expected to have long-term reliability even when used in batteries such as automobiles.

[0053] Here, the terminal connection structure on the negative electrode side of the battery will be described with an example of its configuration.

[0054] <Configuration example 1> As Configuration Example 1, FIG. 7 shows a terminal connection structure on the negative electrode side of a battery in which the clad structure 1 shown in FIG. 1 is used as a battery terminal component. In this Configuration Example 1, the battery terminal component 1 electrically connects the negative electrode side component 2 and the connection component 3. The negative electrode side component 2 shown in Configuration Example 1 is inserted into the second recess 15 of the clad structure 1 (battery terminal component 1). This insertion structure is preferably an interference fit, and more preferably, the negative electrode side component 2 and the leg portion 13 are joined by laser welding or the like. The negative electrode side component 2 is a conductive component electrically connected to the negative electrode in the battery and is an outlet port on the negative electrode side. The negative electrode side component 2 is generally made of a copper material.

[0055] On the other hand, the connection part 3 is joined to the upper flange surface 12A of the flange portion 12 of the clad structure 1 (battery terminal part 1) by laser welding, ultrasonic welding, or the like. The connection part 3 is a conductive part used outside the battery. The connection part 3 is a conductive part such as a bus bar for electrically connecting to other batteries, and can electrically connect multiple batteries to form a battery pack. The connection part 3 is generally made of copper, nickel, or aluminum, but in recent years, aluminum has been preferred for its weight reduction and other reasons.

[0056] When electrically connecting a negative electrode side component 2 made of copper and a connection component 3 made of aluminum, as in Configuration Example 1, it is preferable to use a clad structure 1 (battery terminal component 1) composed of a copper layer 17 made of substantially the same copper material as the negative electrode side component 2 and an aluminum layer 16 made of substantially the same aluminum material as the connection component 3. This facilitates both the electrical connection between the negative electrode side component 2 and the copper layer 17 and the electrical connection between the connection component 3 and the aluminum layer 16, and also enables the bonding strength of both connections to be sufficiently increased.

[0057] <Configuration example 2> As Configuration Example 2, FIG. 8 shows a terminal connection structure on the negative electrode side of a battery using the clad structure 1 shown in FIG. 1 as a battery terminal component. The negative electrode side component 2 shown in Configuration Example 2 is plate-shaped with a through-hole, and the battery terminal component 1 is inserted into the through-hole. This insertion structure can be made into a loose fit or a clearance fit by providing a seal 4 between the negative electrode side component 2 and the flange 12 of the clad structure 1 (battery terminal component 1). Furthermore, Configuration Example 2 employs a crimping structure in which the leg portions 13 of the clad structure 1 (battery terminal component 1) are bent outward. This crimping structure stably fixes the negative electrode side component 2 by sandwiching it between the leg portions 13 and the flange 12. In this case, the negative electrode side component 2 and the leg portions 13 are preferably joined by laser welding or the like.

[0058] On the other hand, the connection part 3 is joined to the upper flange surface 12A of the flange portion 12 of the clad structure 1 (battery terminal part 1) by laser welding, ultrasonic welding, or the like. The connection part 3 is a conductive part used outside the battery. The connection part 3 is a conductive part such as a bus bar for electrically connecting to other batteries, and can electrically connect multiple batteries to form a battery pack. The connection part 3 is generally made of copper, nickel, or aluminum, but in recent years, aluminum has been preferred for its weight reduction and other reasons.

[0059] When electrically connecting a negative electrode side component 2 made of copper and a connection component 3 made of aluminum, as in Configuration Example 2, it is preferable to use a clad structure 1 (battery terminal component 1) composed of a copper layer 17 made of substantially the same copper material as the negative electrode side component 2 and an aluminum layer 16 made of substantially the same aluminum material as the connection component 3. This facilitates both the electrical connection between the negative electrode side component 2 and the copper layer 17 and the electrical connection between the connection component 3 and the aluminum layer 16, and also enables the bonding strength of both connections to be sufficiently increased.

[0060] As described above, the battery terminal component 1 according to the present invention can electrically connect the negative electrode side component 2 and the connection component 3 even if the negative electrode side component 2 has a different shape or connection method, as in the above configuration examples 1 and 2. From this perspective, the battery terminal component 1 is expected to be put to practical use. [Explanation of symbols]

[0061] <Figures 1, 7, and 8> 1: Clad structure (battery terminal parts) 2: Negative electrode part 3: Connection parts 4: Sticker 10: Base, 10A: Upper base, 10B: Lower base 11: Wall, 11A: Inner wall surface (11Aa: Vertical wall surface, 11Ab: Slanted wall surface), 11B: External wall surface 12: flange portion, 12A: upper flange surface, 12B: lower flange surface, 12C: outer flange surface 13: Leg, 13A: Inner leg surface, 13B: Outer leg surface, 13C: Lower leg surface 14: First recess 15: Second recess 16: Aluminum layer (Al layer) 17: Copper layer (Cu layer) <Figure 3> 100: Clad piece 116: Aluminum layer (Al layer) 117: Copper layer (Cu layer) <Figure 4> 200: First molded body 210: Base, 210A: Upper base, 210B: Lower base 211: Wall, 211A: Inner wall surface (211Aa: Vertical wall surface, 211Ab: Slanted wall surface), 211B: External wall surface 212: flange portion, 212A: upper flange surface, 212B: lower flange surface, 212C: outer flange surface 214: First recess 216: Aluminum layer (Al layer) 217: Copper layer (Cu layer) <Figure 5> 300: Second molded body 310: Base, 310A: Upper base, 310B: Lower base 311: Wall, 311A: Internal wall surface (311Aa: Vertical wall surface, 311Ab: Slanted wall surface), 311B: External wall surface 312: flange portion, 312A: upper flange surface, 312B: lower flange surface, 312C: outer flange surface 314: First recess 316: Aluminum layer (Al layer) 317: Copper layer (Cu layer) <Figure 6> 400: Third molded body 410: Base, 410A: Upper base, 410B: Lower base 411: wall portion, 411A: inner wall surface (411Aa: vertical wall surface, 411Ab: inclined wall surface), 411B: outer wall surface 412: flange portion, 412A: upper flange surface, 412B: lower flange surface, 412C: outer flange surface 413: Leg, 413A: Internal leg surface, 413B: External leg surface, 413C: Lower leg surface 414: First recess 415: Second recess 416: Aluminum layer (Al layer) 417: Copper layer (Cu layer)

Claims

1. a base having an upper surface and a lower surface; a wall portion having an inner wall surface and an outer wall surface extending upward from the outer edge of the upper bottom surface; a flange portion including upper and lower flange surfaces extending in a radial direction perpendicular to the wall portion from an end of the wall portion extending upward, and an outer flange surface at the end extending in the radial direction; a leg portion including an inner leg surface and an outer leg surface extending downward from the outer edge of the lower bottom surface, and a lower leg surface at an end extending downward; a first recess defined by the upper bottom surface and the inner wall surface; a second recess defined by the lower bottom surface and the inner leg surface, a first surface extending from the upper bottom surface, through the inner wall surface, to the upper flange surface is made of an aluminum material; A clad structure in which a second surface extending from the lower bottom surface, through the inner leg surface, the lower leg surface, the outer leg surface and the outer wall portion, to the lower flange surface is made of copper material.

2. The cladding structure according to claim 1 , wherein the inner wall surface of the wall portion is composed of a vertical wall surface extending upward from the upper bottom surface of the base portion and an inclined wall surface connecting from the vertical wall surface to the upper flange surface of the flange portion.

3. The cladding structure according to claim 1 or 2, wherein the outer flange surface of the flange portion has a boundary between the first surface continuing from the upper flange surface and the second surface continuing from the lower flange surface.

4. a base having an upper surface and a lower surface; a wall portion having an inner wall surface and an outer wall surface extending upward from the outer edge of the upper bottom surface; a flange portion including upper and lower flange surfaces extending in a radial direction perpendicular to the wall portion from an end of the wall portion extending upward, and an outer flange surface at the end extending in the radial direction; a leg portion including an inner leg surface and an outer leg surface extending downward from the outer edge of the lower bottom surface, and a lower leg surface at an end extending downward; a first recess defined by the upper bottom surface and the inner wall surface; a second recess defined by the lower bottom surface and the inner leg surface, a first surface extending from the upper bottom surface, through the inner wall surface, to the upper flange surface is made of an aluminum material; A battery terminal component in which a second surface extending from the lower bottom surface, through the inner leg surface, the lower leg surface, the outer leg surface, and the outer wall portion, to the lower flange surface is constructed using a clad structure made of copper material.

5. 5. The battery terminal component according to claim 4, wherein the inner wall surface of the wall portion comprises a vertical wall surface extending upward from the upper bottom surface of the base portion and an inclined wall surface connecting from the vertical wall surface to the upper flange surface of the flange portion.

6. The battery terminal part according to claim 4 , wherein the outer flange surface of the flange portion has a boundary between the first surface continuing from the upper flange surface and the second surface continuing from the lower flange surface.

Images