Battery Terminal Component With Ultrasonic Joining and Crimp Gaps
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Solution Overview
Problem
Challenges exist in achieving strong electroconductivity and joining strength between dissimilar metals used in secondary battery terminals, particularly when ultrasonic vibration interferes with crimped structures during ultrasonic joining.
Innovation Solution
A terminal component design involving a first metal with a shaft and fitting portion, ultrasonically joined and crimped into a second metal with a recess, featuring gaps between the fitting portion and recess to facilitate improved joining strength and electroconductivity, using a combination of ultrasonic joining and crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dissimilar metals are crimped together to improve joining strength, then mechanical fastening strength is improved, but the crimped structure interferes with ultrasonic vibrations during subsequent ultrasonic joining
Solution Approach 1:
The invention divides the joining process into two distinct stages: first crimping the dissimilar metals to establish mechanical fastening, then performing ultrasonic joining on the crimped structure. This segmentation allows each process to be optimized independently, with the crimping providing initial strength and the ultrasonic joining enhancing the bond without being hindered by the crimped geometry.
2Reliability
If ultrasonic joining is performed on crimped dissimilar metals, then electroconductivity is improved, but the crimped structure interferes with the ultrasonic vibrations
Solution Approach 1:
The invention performs crimping as a preliminary action before ultrasonic joining. The crimping process prepares the dissimilar metals by establishing initial mechanical contact and alignment, which then facilitates the subsequent ultrasonic joining process. This preliminary mechanical fastening ensures that the ultrasonic vibrations can effectively improve electroconductivity without the metals shifting or misaligning during the process.
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
Enhances the joining strength and maintains electroconductivity between dissimilar metals, reducing deformation and ensuring long-term performance of battery terminals.
Implementation Method 1
Electroconductivity between dissimilar metals constituting external terminals can be improved by joining them by ultrasonic joining
Implementation Method 2
The joining strength between dissimilar metals can be improved by mechanically fastening them together using a method such as crimping
Data Source
AI summary
The terminal component disclosed herein is a terminal component for use in a terminal for secondary batteries. The terminal component includes a first metal and a second metal having a recess. The first metal includes a shall having a pair of flat surfaces and a fitting portion formed at one end of the shaft in the major axis direction. At the boundary between the first metal and the second metal, a joining portion joined by ultrasonic, joining and a crimping portion where the fitting portion of the first metal is fitted into the recess of the second metal are formed. A gap is formed between the recess and the fitting portion in the facing direction in which the gap faces the flat surfaces in plan view.