Diffusion-Bonded Battery Terminal Structure for Vibration Durability
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Solution Overview
Problem
Secondary battery terminals made of different metals face challenges in maintaining joint strength and conductivity under external forces such as vibrations, leading to potential durability issues.
Innovation Solution
A terminal component is designed with a joint portion between two metals joined by metal diffusion, where the second metal has an insulating portion except at the joint, enhancing joint strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different metals are used for terminal components to enhance weldability and conductivity, then electrical performance is improved, but joint strength and durability under external forces deteriorate
Solution Approach 1:
The terminal component is divided into multiple metal layers (first metal layer and second metal layer) with distinct functions. The first metal layer provides weldability and electrical conductivity, while the second metal layer provides mechanical strength and vibration resistance. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The invention uses a composite structure of different metals (e.g., copper and aluminum) where the first metal layer and second metal layer are bonded together. This composite material approach combines the advantageous properties of different metals - copper provides excellent electrical conductivity and weldability, while aluminum provides lightweight strength and vibration resistance.
2Strength
If metal diffusion is used to join different metals, then joint strength is improved, but manufacturing complexity increases
Solution Approach 1:
The insulating coating is applied to the second metal layer before the metal diffusion bonding process. This preliminary action protects the second metal layer during manufacturing and handling, while the controlled removal or penetration of this coating at the bonding interface enables the metal diffusion process to occur effectively.
Solution Approach 2:
The invention controls the metal diffusion process by adjusting parameters such as temperature, pressure, and time to achieve optimal joint strength. By carefully controlling these parameters, the manufacturing process becomes more predictable and manageable, reducing overall complexity despite the advanced bonding technique used.
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 terminal component achieves high joint strength and maintains conductivity, ensuring durability even under external forces like vibrations, by using metal diffusion and insulating processes like anodic oxide coating or nickel plating.
Implementation Method 1
A joint portion is disposed at an interface between the first metal and the second metal, the joint portion being joined by metal diffusion
Implementation Method 2
The insulating portion may be a layer formed by any one of anodic oxide coating, nickel plating, or resin coating
Implementation Method 3
The insulating portion may be a layer formed by any one of anodic oxide coating, nickel plating, or resin coating
Implementation Method 4
The preparing the second metal may include providing the to-be-joint portion in a surface of the second metal subjected to the insulating process by removing the insulating portion with any one of an ultrasonic process, a cutting process, or a laser abrasion process
Implementation Method 5
The preparing the second metal may include providing the to-be-joint portion in a surface of the second metal subjected to the insulating process by removing the insulating portion with any one of an ultrasonic process, a cutting process, or a laser abrasion process
Data Source
AI summary
A terminal component disclosed here includes a first metal and a second metal on which the first metal is overlaid. A joint portion joined by metal diffusion is formed at an interface between the first metal and the second metal. The second metal includes an insulating portion subjected to an insulating process in a portion except for the joint portion.