Secondary Battery Terminal Joining for Strong Dissimilar-Metal Contact
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Solution Overview
Problem
Existing methods for manufacturing electrode terminals using different metals result in high manufacturing costs and potential deformation due to crimping, leading to insufficient junction strength and conduction between the electrode terminals and bus bars in secondary batteries.
Innovation Solution
A manufacturing method involving ultrasonic joining of two metal members, where one member has a concave part and the other a flange part, allows for pressure contact and crimping, forming a crimped structure with sufficient junction strength and conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding followed by crimping is used to join different metal connection terminals, then conduction and junction strength are improved, but the components may be deformed by crimping
Solution Approach 1:
The invention extracts the harmful crimping step from the manufacturing process. Instead of using crimping to form the cup-shaped structure, the method directly forms the cup-shaped connection terminal from a single piece of conductive material through shaping operations, eliminating the need for subsequent crimping that causes deformation.
Solution Approach 2:
The invention replaces the mechanical crimping system with a direct shaping process. The cup-shaped structure is formed through controlled plastic deformation during manufacturing rather than through impact crimping, substituting a precise forming mechanism for a rough mechanical operation.
2Strength
If cladding material is used to form electrode terminal, then conduction and junction strength are improved, but manufacturing cost increases
Solution Approach 1:
The invention applies local quality by creating a cup-shaped structure with specific geometric features that concentrate contact area and improve mechanical interlocking. The localized shaping provides enhanced junction strength at critical interfaces without requiring expensive cladding materials throughout the entire component.
Solution Approach 2:
The invention creates a composite structure through the cup-shaped geometry that combines different functional zones within a single material. The shaped structure provides both electrical conduction and mechanical strength through its geometry rather than through material composition, avoiding the need for multi-layer cladding materials.
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 method enables favorable conduction and strong junction between different metal species, reducing manufacturing costs while maintaining high conduction and junction strength, suitable for use in secondary batteries.
Implementation Method 1
fixing the first member and the second member to each other by ultrasonic pressure contact, with the ultrasonic pressure contact being performed by applying an ultrasonic wave vibration while applying a pressure
Implementation Method 2
one metal is drawn to and is brought into pressure contact with the other metal due to the pressure and the vibration applied to the two kinds of metals, resulting in the formation of the crimped structure
Implementation Method 3
the components manufactured by such a method attains favorable conduction due to metal joining between two kinds of metals
Implementation Method 4
attains favorable conduction due to metal joining between two kinds of metals, and moreover due to a crimped structure thereof
Data Source
AI summary
Provided is a method for manufacturing an electrode terminal formed of different kinds of metals excellent injunction strength. The manufacturing method of a terminal herein disclosed includes the following steps of: preparing a first member and a second member each made of a metal and forming the terminal, with the first member being formed in a sheet shape and having at one surface thereof a concave part for allowing a part of the second member to be fitted therein, and with the second member having a flange part to be accommodated in the concave part; and fixing the first member and the second member to each other by ultrasonic pressure contact, with the ultrasonic pressure contact being performed by applying an ultrasonic wave vibration while applying a pressure in a direction of stacking of the first member and the second member in a state where the flange part of the second member is arranged in the concave part of the first member, thereby extending the flange part, and bringing a part of the extended flange part into pressure contact with an inner wall surface of the concave part.