Battery Terminal Joint Structure for Vibration-Stable Conduction
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Solution Overview
Problem
Conventional battery terminals are prone to instability and connection failures due to external forces like vibrations, which can cause gaps between the rivet member and the conductive member, leading to unstable conduction and increased resistance.
Innovation Solution
A terminal design featuring a first conductive member made of aluminum or aluminum alloy and a second conductive member made of copper or copper alloy, with a metal joint that includes a fused and solidified portion, reducing the area of the second sub-portion to 35% or less of the first sub-portion, and using a fastener and metal joint to secure the components, providing a stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rivet member is swaged to connect to a conductive member, then mechanical connection is achieved, but the connection becomes unstable under external forces like vibrations
Solution Approach 1:
The connection structure is divided into two independent connection methods: a fastener for mechanical connection and a metal joint for electrical connection. This segmentation allows each connection type to optimize its function independently, preventing the mechanical connection from compromising electrical reliability under vibration.
Solution Approach 2:
The metal joint acts as an intermediary element that provides a stable electrical connection path independent of the mechanical fastener. This intermediary connection ensures that electrical conductivity is maintained even when the mechanical fastener experiences stress or distortion from external forces.
2Reliability
If the conduction path area is reduced, then conduction resistance increases, but a wider conduction path increases the risk of cracks in the fused portion
Solution Approach 1:
The fused portion has non-uniform area distribution with a first sub-portion and a second sub-portion, where the second sub-portion area is 35% or less of the first. This local quality variation concentrates the conduction path in the stronger first sub-portion while limiting crack propagation risk in the weaker second sub-portion, optimizing both conductivity and structural integrity.
3Area of stationary object
If Cu penetration into the first sub-portion increases, then conduction path area increases, but cracks occur in the fused and solidified portion
Solution Approach 1:
The area ratio parameter of the second sub-portion is controlled to be 35% or less of the first sub-portion. This parameter change limits the extent of Cu penetration into the aluminum-based first sub-portion, preventing excessive intermetallic compound formation that would cause cracks while maintaining adequate conduction path area.
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 design enhances conduction reliability and reduces conduction resistance by maintaining intimate contact between the conductive members, preventing cracks, and ensuring a wide conduction path, thus improving the performance of battery terminals.
Implementation Method 1
a metal joint metal-joining the first conductive member and the flange of the second conductive member to each other at a location away from the fastener. The metal joint includes a fused and solidified portion in which the first conductive member and the second conductive member are fused together.
Data Source
AI summary
A battery disclosed herein includes a terminal. The terminal includes: a first conductive member; a second conductive member electrically connected to the first conductive member; a fastener mechanically securing the first conductive member and the second conductive member to each other; and a metal joint metal-joining the first conductive member and the second conductive member to each other. The metal joint includes a fused and solidified portion. The fused and solidified portion includes a first sub-portion formed in the first conductive member, and a second sub-portion formed in the second conductive member. When viewed in cross section, an area of the second sub-portion is 35% or less of an area of the first sub-portion.