Interlocking Bimetal Ribbon Connector for Tensile-Stable Cell Joining
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Solution Overview
Problem
Existing band-shaped connectors made of two different metallic materials for galvanic cells are prone to separation under mechanical stress, particularly tensile load, due to instability in the connection between the materials.
Innovation Solution
A band-shaped connector with a connecting surface featuring interlocking toothings, including undercuts, that ensures a positive and form-fitting connection between the two metallic materials, preventing separation by aligning projections and cavities to create a stable mechanical bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining techniques are used to connect two different metallic materials, then the manufacturing process is simple, but the connection stability is insufficient and the materials separate under mechanical stress
Solution Approach 1:
The connecting surface is segmented into multiple interlocking teeth instead of a single continuous joint. Each tooth consists of protrusions on one material and corresponding recesses on the other material, creating distributed connection points that prevent separation under stress while maintaining manufacturing feasibility through standardized repeating patterns.
Solution Approach 2:
The joining structure implements local quality by creating specific geometric features (protrusions and recesses) only at the interface region where connection is needed. The bulk materials remain unchanged, allowing the use of different metallic materials with their inherent properties while providing enhanced connection stability only where required.
2Strength
If a larger overlap area is used to increase joint stability, then the connection strength improves, but the connector dimensions and complexity increase
Solution Approach 1:
The solution transitions from increasing overlap area in the planar dimension to creating interlocking features in the vertical dimension. The protrusions and recesses extend into the thickness of the materials, providing mechanical interlocking that achieves high joint strength without increasing the lateral dimensions of the connector.
3Reliability
If complex interlocking profiles are created to prevent separation, then the mechanical connection stability improves, but the manufacturing complexity and alignment requirements increase
Solution Approach 1:
The interlocking teeth feature asymmetric protrusions and recesses that are designed to mate together in a specific orientation. This asymmetric geometry provides self-aligning characteristics during assembly, reducing the precision requirements for alignment while ensuring stable mechanical connection once assembled.
Solution Approach 2:
The protrusions and recesses are pre-formed on the respective metallic materials before assembly. This preliminary action allows the components to be manufactured separately with standard tolerances, then assembled together where the pre-formed features automatically provide the interlocking connection without requiring complex real-time alignment during assembly.
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 mechanically stable connection that resists separation under tensile force, making the band-shaped connector robust and suitable for mass production while maintaining cost-effectiveness.
Implementation Method 1
the metallic materials of the strips are firmly joined together by roll cladding
Implementation Method 2
cold-roll cladding process
Data Source
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AI summary
The invention relates to a band-shaped connector made of metal, wherein the length and width of the band-shaped connector are greater than the thickness of the band-shaped connector, the band-shaped connector comprising a first metallic material (41) and a second metallic material (42), wherein the first material (41) and the second material (42) are directly and positively connected and joined to one another via a connecting surface (50), wherein the connecting surface (50) has at least partially opposing, positively interlocking and interlocking teeth (43, 52) of the first material (41) and the second material (42) along the width of the band-shaped connector.The invention also relates to the use of such a ribbon connector for connecting galvanic cells, a galvanic cell with several galvanic cells, wherein the galvanic cells are connected and electrically contacted by at least one such ribbon connector, and a method for producing a connecting ribbon and for producing ribbon connectors from the connecting ribbon.