Ultrasonic-Bonded Battery Terminal Rib Structure for Stable Joining
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Solution Overview
Problem
Conductive members in electrical energy storage devices face instability and damage during mechanical bonding processes, such as fastening and caulking, which can lead to unreliable connections, especially when ultrasonic bonding is performed after these steps.
Innovation Solution
A terminal design featuring a first conductive member with a concave part and a second conductive member inserted into it, bonded using ultrasonic waves, with a rib on the outer peripheral side to enhance stability and prevent deformation, and a fastening part for mechanical stability, ensuring a reliable connection between the conductive members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical bonding (fastening or caulking) is performed on conductive members, then the conductive members can be fixed and connected, but burden is applied on the conductive member or metal bonding part leading to deformation or damage and unstable connection state
Solution Approach 1:
The ultrasonic bonding is performed before the caulking step to create a strong metal bonding part before mechanical fastening. This preliminary bonding ensures that the conductive members are already strongly connected before any mechanical burden is applied during subsequent caulking operations, preventing deformation and maintaining connection stability
Solution Approach 2:
The invention changes the sequence of manufacturing parameters by performing ultrasonic bonding at an earlier stage before mechanical fastening. This parameter change in process sequencing allows the metal bonding to occur under optimal conditions without the interfering effects of subsequent mechanical loads
2Productivity
If ultrasonic bonding is performed after caulking step, then the manufacturing process can be completed, but the ultrasonic bonding part is damaged and connection state becomes unstable
Solution Approach 1:
Ultrasonic bonding is performed as a preliminary step before caulking and other mechanical fastening operations. This ensures the bonding part is created when no mechanical burdens have yet been applied, and subsequent steps do not compromise the bonding integrity
Solution Approach 2:
The conventional sequence is inverted by performing ultrasonic bonding before mechanical fastening rather than after. This reversal of the manufacturing sequence prevents the mechanical processes from damaging the bonding part while maintaining overall manufacturing efficiency
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 proposed terminal design achieves a high-reliability connection between conductive members by stabilizing the ultrasonic bonding process and reducing the risk of damage during manufacturing, thereby enhancing the overall performance and durability of the electrical energy storage device.
Implementation Method 1
an ultrasonic bonding part where the first conductive member and the second conductive member are bonded to each other with ultrasonic waves
Data Source
AI summary
The present disclosure provides a terminal including a first conductive member that is formed of a first metal and includes a concave part, a second conductive member that is formed of a second metal and includes a part disposed in the concave part, and an ultrasonic bonding part where the first conductive member and the second conductive member are bonded to each other with ultrasonic waves. The first conductive member includes a rib that is provided on an outer peripheral side relative to the ultrasonic bonding part and that protrudes from a second surface of the first conductive member.