Battery Terminal Joint Structure for Load-Resistant Coupling
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Solution Overview
Problem
The existing terminals for electricity storage devices face reliability issues in the coupling portion between conductive members due to applied loads from external coupling members, which can lead to reduced conduction and potential disconnection.
Innovation Solution
A terminal design featuring a first conductive member made of a softer metal and a second conductive member made of a harder metal, with a flange portion, shaft portion, and metallic joining portions, including recessed portions and protrusions that enhance the mechanical and electrical connection, reducing the risk of disconnection under load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductive members are coupled together to form a terminal, then the terminal can provide electrical connection functionality, but the coupling portion becomes vulnerable to disconnection under applied loads
Solution Approach 1:
The coupling portion is divided into multiple engagement regions: the recessed portion in the first conductive member and the protrusion in the second conductive member. This segmentation allows the load to be distributed across multiple contact points rather than concentrated at a single interface, improving overall coupling reliability under external loads.
Solution Approach 2:
The protrusion of the second conductive member is inserted into the recessed portion of the first conductive member, creating a nested structure. This nesting design provides mechanical interlocking that prevents separation under tensile loads while maintaining electrical conductivity through the metallic joining portions at the interface.
2Reliability
If the conductive members are made of different metals, then the terminal can optimize electrical and mechanical properties, but the joining process becomes more complex
Solution Approach 1:
Different regions of the conductive members have different properties: the protrusion and recessed portion are designed with specific geometries for mechanical engagement, while the joining surfaces are prepared for metallic bonding. This local differentiation allows optimal joining of dissimilar metals by tailoring the interface characteristics to the specific metal pair being joined.
Solution Approach 2:
The terminal utilizes a composite structure of dissimilar metals (first conductive member and second conductive member made of different metals) joined through metallic bonding at the interface. This composite approach leverages the complementary properties of different metals while the recessed-protrusion design facilitates the joining process.
3Reliability
If the coupling portion is designed with simple geometry, then the manufacturing is easier, but the load distribution is poor leading to reduced reliability
Solution Approach 1:
The coupling interface is segmented into distinct functional zones: the recessed portion providing mechanical engagement, the protrusion providing structural support, and the joining portions providing electrical and metallurgical connection. This segmentation improves load distribution while keeping each individual feature geometrically simple for manufacturing.
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
The enhanced terminal design achieves high reliability and durability by distributing loads effectively and maintaining good conductivity between the conductive members, even under external stress, such as from bus bars.
Implementation Method 1
a first metal joining portion metallically joined to the first conductive member on an upper surface of the flange portion... a second metal joining portion where the first conductive member and the second conductive member are metallically joined to each other
Data Source
AI summary
A terminal includes a first conductive member formed of a first metal and a second conductive member formed of a second metal that is different from the first metal. The second conductive member includes a flange portion and a shaft portion provided on one surface of the flange portion. The second conductive member includes a first metal joining portion metallically joined to the first conductive member on an upper surface of the flange portion. The second conductive member includes a protrusion at a side closer to an outer periphery than the first metal joining portion. The first conductive member includes a first recessed portion that is fitted to the protrusion. The second conductive member includes a second metal joining portion where the first conductive member and the second conductive member are metallically joined to each other at the first recessed portion and the protrusion.