Dissimilar-Metal Battery Terminal Sealing Against Liquid Corrosion
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Solution Overview
Problem
The existing terminals configured with dissimilar metals and penetration holes are prone to corrosion due to the invasion of electrically conductive liquids, which accelerates positive-ionization and corrosion on metals with lower electric potential.
Innovation Solution
A terminal configuration that includes a first conductive member with a penetration hole and a second conductive member covering it, with the boundary area between them covered by tape or a resin member to prevent liquid ingress and exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a penetration hole is provided on the terminal upper part to provide an escape path for gas or heat during welding, then the welding process is improved, but the corrosion resistance deteriorates due to liquid invasion
Solution Approach 1:
The terminal is divided into multiple material layers (aluminum layer and copper layer) with distinct functions. The aluminum layer provides corrosion resistance and forms the outer surface, while the copper layer provides electrical conductivity and structural strength. This segmentation allows each material to optimize its own properties without compromising the other.
Solution Approach 2:
The terminal uses a composite structure of dissimilar metals (aluminum and copper) joined together. The aluminum layer is formed on the copper layer through electroplating or cladding, creating a composite material that combines the corrosion resistance of aluminum with the electrical conductivity and strength of copper. This composite structure resolves the contradiction by allowing the terminal to have both good welding characteristics and corrosion resistance.
2Ease of operation
If dissimilar metals are joined to implement favorable join with external members, then the ease of operation is improved, but the corrosion resistance deteriorates due to accelerated positive-ionization at the boundary
Solution Approach 1:
The terminal structure implements local quality by having different materials at different locations. The aluminum layer is positioned at the outer surface where it contacts the environment, providing localized corrosion resistance. The copper layer is positioned internally where it provides electrical conductivity and structural support. This spatial differentiation of material properties allows the terminal to resist corrosion at the critical boundary surface while maintaining the benefits of dissimilar metal joining.
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 effectively suppresses liquid invasion and subsequent corrosion of the dissimilar metals, enhancing the corrosion resistance of the terminal.
Implementation Method 1
a boundary part between a vicinity of the penetration hole of the first conductive member and the second conductive member is covered with a tape and/or a resin member to prevent the boundary part from being exposed
Data Source
AI summary
A herein disclosed terminal includes a first conductive member and a second conductive member that is electrically connected to the first conductive member. The first conductive member and the second conductive member are composed of mutually different metals. The first conductive member includes a penetration hole. The second conductive member is arranged to cover the penetration hole. Then, a boundary part between a vicinity of the penetration hole of the first conductive member and the second conductive member is covered with a tape and/or a resin member to prevent the boundary part from being exposed.