Rechargeable Battery Pillar Terminal Dissimilar Metal Bonding
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Solution Overview
Problem
The challenge lies in bonding aluminum and copper terminals in rechargeable battery modules, as their different melting points complicate welding, leading to increased manufacturing costs and decreased productivity.
Innovation Solution
The use of a pillar terminal with sections made of different metals, where an intermediate section made of one metal is electroplated on the other, allowing for effective welding and bonding, thereby overcoming the melting point difference issue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding is used to bond aluminum and copper terminals, then bonding is achieved, but manufacturing costs increase and productivity decreases
Solution Approach 1:
The patent introduces an intermediate terminal section made of a third metal that is compatible with both aluminum and copper. This intermediate section acts as a mediator that enables welding between the dissimilar metals without requiring complex friction welding processes, thereby maintaining high productivity while achieving strong bonds.
Solution Approach 2:
The terminal structure uses a composite construction with multiple metal sections (aluminum, copper, and intermediate metal) joined together. This composite approach allows each section to be optimized for its specific function and compatibility requirements, solving the bonding problem between dissimilar metals through material composition rather than complex joining processes.
2Strength
If friction welding is used to bond aluminum and copper terminals, then bonding is achieved, but manufacturing costs increase
Solution Approach 1:
The intermediate terminal section made of a third metal serves as a mediator that simplifies the manufacturing process. Instead of using expensive and complex friction welding, the intermediate section enables straightforward welding operations between compatible metal pairs, significantly reducing manufacturing costs while maintaining bond strength.
Solution Approach 2:
The composite terminal structure with multiple metal sections allows for simplified manufacturing processes. Each metal section can be manufactured and prepared separately, then joined using standard welding techniques, which is more cost-effective than friction welding while ensuring adequate bonding strength.
3Device complexity
If aluminum and copper terminals are bonded directly, then structure is simplified, but welding is difficult due to different melting points
Solution Approach 1:
The intermediate terminal section made of a third metal acts as a mediator between aluminum and copper. This third metal is selected to be weldable with both aluminum and copper, creating a three-section composite structure that is actually simpler to manufacture than direct bonding, as each interface can be welded using standard techniques without dealing with the incompatible melting points of aluminum and copper directly.
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
This solution enables efficient bonding of aluminum and copper terminals, reducing manufacturing costs and improving productivity while ensuring sufficient strength at the welded interface.
Implementation Method 1
The intermediate section may be made of the second metal and electroplated on a surface of the first section
Implementation Method 2
The intermediate section may be welded to the second section
Data Source
AI summary
A rechargeable battery including a pillar terminal electrically connected to a positive or negative electrode. The pillar terminal includes a first section made of a first metal, a second section made of a second metal, and a third section between the first and second sections. The third section is made of the first metal or the second metal. The third section is welded to the first section and is electroplated to the second section.