Battery Terminal Flange Structure for Electrolyte-Resistant Joining
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Solution Overview
Problem
The existing terminals for electricity storage devices face reliability issues due to damage from electrolyte exposure, particularly at the boundary between conductive members, leading to corrosion and reduced fastening portion reliability.
Innovation Solution
A terminal design featuring a first conductive member with a recessed portion and a second conductive member with a flange and shaft, where the flange's small diameter portion is positioned further from the shaft, and the outer diameter of the small diameter portion is less than 9/10 of the large diameter portion, enhancing mechanical fastening and reducing electrolyte exposure risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the boundary between conductive members is exposed to electrolyte, then the terminal structure is simple, but corrosion occurs and reliability decreases
Solution Approach 1:
The flange portion is nested within the recessed portion of the first conductive member, creating a protective enclosure. The small diameter portion fits into the recessed portion while the large diameter portion remains exposed, forming a nested structure that shields the coupling interface from electrolyte exposure and prevents corrosion.
Solution Approach 2:
The flange portion is designed with non-uniform diameter, featuring a small diameter portion and a large diameter portion. This local variation in geometry allows the small diameter portion to be positioned deeper in the recessed portion, creating a protective barrier against electrolyte while maintaining structural integrity and electrical conductivity.
2Reliability
If the small diameter portion is positioned closer to the shaft portion, then the terminal structure is compact, but the fastening portion reliability decreases due to electrolyte exposure
Solution Approach 1:
The flange portion utilizes radial dimension variation with the small diameter portion positioned at a greater radius from the shaft portion than the large diameter portion. This radial arrangement allows the small diameter portion to extend further into the recessed portion, providing electrolyte protection while maintaining a compact overall terminal volume through optimized spatial distribution.
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 configuration increases the reliability of the coupling between conductive members by minimizing electrolyte exposure and corrosion, thereby enhancing the durability and stability of the terminal.
Implementation Method 1
The outer peripheral side surface of the small diameter portion includes a fastening portion mechanically fastened to an inner surface of the first recessed portion
Implementation Method 2
the first conductive member includes a metal joining portion metallically joined to the flange portion
Data Source
AI summary
A terminal includes a first conductive member and a second conductive member. The first conductive member includes a first recessed portion. The second conductive member includes a flange portion and a shaft portion. At least a portion of the flange portion is arranged in the first recessed portion. The first conductive member includes a metal joining portion metallically joined to the flange portion. The flange portion includes a large diameter portion and a small diameter portion. An outer diameter of the small diameter portion is equal to or less than 9/10 of an outer diameter of the large diameter portion. An outer peripheral side surface of the small diameter portion includes a fastening portion mechanically fastened to an inner surface of the first recessed portion.