Terminal Component Recess Design for Dissimilar Metal Joining
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Solution Overview
Problem
When dissimilar metals are joined using metal joining techniques like ultrasonic joining, the joining strength between the terminal and the metal is often insufficient, leading to surface roughening and deformation, which increases production steps and reduces productivity.
Innovation Solution
A terminal component design where a first metal with a recess wider inside than outside is overlapped with a second metal, allowing the second metal to enter the recess and be metal-joined to the inner surface, ensuring strong mechanical and conductive joining without the need for additional caulking steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic joining is used to join dissimilar metals, then the joining process is simplified, but the joining strength becomes insufficient
Solution Approach 1:
The invention creates a composite structure where dissimilar metals (first metal and second metal) are joined through a recess configuration. The second metal enters the recess of the first metal and is metal-joined to the inner surface, forming a composite joint structure that combines the advantages of both materials while achieving sufficient joining strength without requiring additional caulking steps.
Solution Approach 2:
The invention utilizes the depth dimension by creating a recess in the first metal that extends inward. The second metal enters this recess and is joined to the inner surface, effectively using the third dimension (depth) to increase the joining area and strength without increasing the surface footprint or requiring additional external joining steps.
2Strength
If high energy is applied to ensure required joining strength, then the joining strength is sufficient, but the surface of the external terminal becomes roughened or deformed
Solution Approach 1:
The invention applies joining energy locally within the recess area rather than across the entire surface. The recess is formed at a specific location where high energy joining is needed, while the surrounding surface of the external terminal remains unaffected and maintains its original quality. This localized approach allows sufficient joining strength without widespread surface roughening or deformation.
Solution Approach 2:
The joining process is segmented into two functional zones: the recess area where high energy metal joining occurs to ensure strength, and the surrounding surface area that remains untouched and maintains its original quality. This segmentation allows the joining strength requirement to be met without compromising the overall surface quality of the external terminal.
3Strength
If a caulking structure is added after joining, then the joining strength is improved, but the number of production steps increases
Solution Approach 1:
The invention merges the joining function and the structural reinforcement function into a single integrated process. The recess configuration serves both as the joining interface for metal joining and as the structural feature that provides mechanical reinforcement. This eliminates the need for a separate caulking step, maintaining high joining strength while improving production efficiency.
Solution Approach 2:
The recess structure serves multiple functions simultaneously: it provides the interface for ultrasonic metal joining, offers mechanical reinforcement through the interference fit of the second metal entering the recess, and eliminates the need for additional caulking operations. This multi-functionality resolves the contradiction between joining strength and production 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
This design enhances joining strength and conductivity between dissimilar metals while reducing production steps and eliminating surface roughening, thus improving productivity and maintaining electrical integrity.
Implementation Method 1
Japanese Patent Application Publication No. 2016-18675 discloses joining a metal member to an external terminal by ultrasonic joining in order to improve the weldability between the external terminal and a bus bar.
Data Source
AI summary
A terminal component includes a first metal and a second metal overlapped on the first metal. The first metal is provided with a recess where an inside is wider than an opening at a portion overlapped with the second metal. A part of the second metal has entered the recess of the first metal, and the second metal has a portion that has entered a portion of the recess of the first metal where the inside is wider than the opening, and a recess on a surface opposite to the portion that has entered the recess of the first metal. At least a part of the portion of the second metal that has entered the recess of the first metal is metal-joined to the inner surface of the recess of the first metal.