Dissimilar-Metal Interconnection Joint With Hermetic Corrosion Sealing

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Solution Overview

Problem

Galvanic corrosion occurs at the joint portions of device interconnection members made of dissimilar metals, leading to potential failure under vibrations or impacts.

Innovation Solution

A device interconnection member with a resin seal member hermetically sealing the joint portion of dissimilar metals, and using nano-level roughened surfaces with nanocolumns to enhance hermeticity, along with plastic deformation for joining without welding, and a swaged portion design for secure attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dissimilar metals (e.g., aluminum and copper) are joined to connect electrode terminals of different materials, then electrical connection between positive and negative terminals is achieved, but galvanic corrosion occurs at the joint portion

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidgalvanic corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a resin seal member as an intermediary substance between dissimilar metals (aluminum and copper) to prevent direct contact. This mediator isolates the two dissimilar metals, eliminating the galvanic corrosion pathway while maintaining electrical connectivity through the conductive resin material.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The resin seal member creates an inert, corrosion-resistant environment around the joint portion of dissimilar metals. By encapsulating the aluminum-copper joint in a chemically stable resin matrix, the patent prevents exposure to corrosive elements and eliminates the electrochemical reactions that cause galvanic corrosion.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Strength

If welding is used to join conductive members, then strong electrical connection is achieved, but complexity of manufacturing process increases

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing process simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the thermal-mechanical welding process with a simpler mechanical pressing or insertion operation. The conductive members are joined through direct mechanical contact and friction, eliminating the need for complex welding equipment, heat control systems, and skilled welders while maintaining adequate joint strength for electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Prevents corrosion and ensures reliable electrical connection by reducing exposure to air and moisture, enhancing durability against vibrations and impacts, and minimizing part count.

Implementation Method 1

a resin seal member hermetically sealing the joint portion

Methodology Applied

Scientific EffectHermetic sealing:

Implementation Method 2

a first seal portion having a first roughened surface extending over an entire periphery on which first nanocolumns stand numerously

Methodology Applied

Scientific EffectNano-level roughening:

Implementation Method 3

when the first joined portion and the second joined portion are joined by swaging

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20260018747A1Device interconnection member

Publication Date: 2026.01.15 PRIME PLANET ENERGY & SOLUTIONS INC

AI summary

A device interconnection member for connecting a first electrode terminal made of first metal in one power storage device and a second electrode terminal made of second metal in another power storage device includes a first conductive member made of the first metal and to be connected to the first electrode terminal, a second conductive member made of the second metal and to be connected to the second electrode terminal, a joint portion where a first joined portion of the first conductive member and a second joined portion of the second conductive member are joined, and a resin seal member hermetically sealing the joint portion.