Diffusion-Bonded Battery Terminal with Nickel-Plated Metal Interface
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Solution Overview
Problem
Existing secondary battery terminals formed of dissimilar metals face issues with conductivity and joining strength, particularly when subjected to vibrations, leading to potential corrosion and reduced durability.
Innovation Solution
A terminal component is designed with a first metal (copper) plated with nickel at the boundary surface, joined to a second metal (aluminum) through diffusion, forming a joining portion with controlled nickel thickness to enhance durability and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal component is formed of dissimilar metals to improve conductivity and weldability, then the electrical performance is improved, but the joining interface durability under vibrations deteriorates
Solution Approach 1:
The terminal component uses a composite structure of dissimilar metals (first metal and second metal) where each metal contributes its superior properties - one metal provides conductivity and weldability while the other provides vibration resistance. The metals are joined through diffusion bonding to create a durable interface that maintains both electrical performance and mechanical strength under vibrational conditions.
Solution Approach 2:
The patent applies different metals to different regions of the terminal component based on local functional requirements. The first metal is used where conductivity and weldability are critical, while the second metal is used where vibration resistance is needed. This localized material selection optimizes both electrical performance and joining durability.
2Adaptability or versatility
If dissimilar metals are joined together to form a terminal component, then the functional properties are improved, but the joint strength under external forces deteriorates
Solution Approach 1:
The patent controls the joint strength by adjusting parameters such as the diffusion bonding conditions, interface area, and metal composition ratios. By optimizing these parameters, the joint strength is enhanced to withstand external forces while maintaining the functional advantages of dissimilar metal construction.
3Device complexity
If a simple metal structure is used to reduce complexity, then the manufacturing cost is reduced, but the durability under vibrations deteriorates
Solution Approach 1:
Instead of using a simple single-metal structure, the patent employs a composite structure of two metals joined at their interface. This composite design specifically addresses the vibration durability issue by combining metals with complementary properties, while keeping the overall structure relatively simple and manufacturable.
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 solution provides a high-strength, low-resistance joint that withstands vibrations and corrosion, ensuring reliable electrical connection and improved durability of the secondary battery terminals.
Implementation Method 1
On the first metal, nickel is plated at least on a boundary surface with the second metal
Implementation Method 2
A joining portion joined by diffusion of the metals is formed in a portion of a boundary between the first metal and the second metal
Data Source
AI summary
A terminal component disclosed herein includes a first metal and a second metal stacked on the first metal. On the first metal, nickel is plated at least on a boundary surface with the second metal. A joining portion joined by diffusion of the metals is formed in a portion of a boundary between the first metal and the second metal.