Patent Description:
<CIT> addresses the problem of providing a method capable of easily joining a titanium molding to a gold alloy molding in an exact position, and a joined material. A titanium molding, molded by using a titanium material consisting of pure titanium or titanium alloy essentially consisting of titanium, and a gold alloy molding, consisting of a gold-base alloy material of a gold content greater than or equal to <NUM>%, are butted against each other at their respective joint surfaces and are joined by irradiating the joint surfaces with at least a laser beam.

<CIT> addresses the problem of manufacturing a high-reliability pin terminal by fixing a pin to a terminal main body by welding, and increasing the mechanical and electrical binding force between the pin and the terminal main body. Since the base end of a round pin is coupled with the cylinder section of a terminal main body and welded and fixed to form a pin type terminal, the mechanical and electrical binding force between the round pin and terminal main body is increased. The round pin is inserted to expand the cylinder section, the gap between the round pin and cylinder section is eliminated by the elastic shrinking force of the cylinder section, the adhesion is increased, and the mechanical and electrical binding force is further increased. At the time of assembling, a taper section exists on the inlet side of the cylinder section, the end section of the round pin is made semi-spherical, and the round pin can be easily inserted into the cylinder section. The round pin is held and positioned by the cylinder section and welded with a laser.

<CIT> describes a lead assembly that includes an outer insulative body, at least one conductor disposed within the outer insulative body, and an inner electrode coupled with the at least one conductor. The lead assembly further includes an outer electrode disposed over the inner electrode, where the outer electrode is coupled with at least a portion of the inner electrode outer surface, for example by laser welding or magnetic swaging.

This overview is intended to provide an overview of subject matter of the present patent document. The detailed description is included to provide further information about the present patent document.

The present inventors have recognized, among other things, that the present subject matter can be used to join pieces together, for instance, to form a component for use in various applications, such as, but not limited to, electrochemical cell components. In various examples, the present subject matter is advantageous in that it provides a method of joining pieces formed from materials that are substantially incompatible with other methods of joining. For instance, the present subject matter is advantageous because it provides a method of joining an aluminum piece to a molybdenum piece to form a relatively strong joint between the pieces. Also, the present subject matter is advantageous in that it provides for a consistent and/or qualifiable method of joining two pieces together. The present subject matter can be used to join pieces together even in the event that the pieces are formed from materials that are difficult to attach to one another using one or more other methods of attachment. To better illustrate the devices described herein, a non-limiting list of examples is provided here:.

The present invention relates generally to a joined component and a method of joining metallic elements, compounds, and compositions. More specifically, the present invention relates to a laser brazed component and a method of laser brazing such a component. In some examples, a molybdenum piece is joined to an aluminum piece to form the laser brazed component. In some examples, such a component can be used in electrochemical cell components. In some examples, such a component can be used in a medical device. In further examples, such a component can be used in an implantable medical device. However, the present subject matter is not intended to be so limited. As such, it is contemplated herein that the present subject matter can be used in various other components and/or in various other situations.

In some examples, the present subject matter provides a qualifiable joint between a pin and an aluminum lead for battery technologies. In further examples, the present subject matter can be used to join together a molybdenum pin and an aluminum lead. In still further examples, the present subject matter can be used to join a small-diameter molybdenum pin and a thin aluminum lead. For example, the present subject matter can be used to join together a <NUM>-inch-diameter molybdenum pin and a <NUM>-inch-thick aluminum lead for battery technologies. In other examples, the present subject matter includes a component formed using the joining method described herein. In some examples, qualifiable and laser brazing techniques are described, which allow for joining of small diameter battery configurations. In some examples, qualifiable and laser brazing techniques are described, which allow for joining challenging geometries, such as, for instance, a round pin sitting on a flat lead. With such a configuration, there is relatively little contact between the round pin and the flat lead (essentially, the contact includes a line along the pin at which the lead extends tangentially with respect to the pin). Moreover, such contact can be inconsistent, for instance, if the pin and/or the lead are bent or otherwise deformed from straight. In some examples, the present subject matter relates to joining of molybdenum and aluminum, where a relatively stable, non-brittle joint is formed.

Moreover, the present subject matter describes forming a joint between a molybdenum pin and an aluminum lead, for instance, that can be brazed using a laser, where the aluminum lead forms around the molybdenum pin so the aluminum lead can be melted over the radius of the molybdenum pin. Such joint designs provide for the aluminum piece to be melted over the molybdenum piece with minimum melting/mixing of molybdenum into the joint pool. The present methods accordingly minimize the formation of brittle joints borne out of intermetallic methods. Advantages of the present methods include, but are not limited to, the formation of aluminum lead around a molybdenum pin to create a relatively strong joint, which functions to relieve stress on the joint and allows for a proper joint pool composition to help avoid formation of a brittle joint.

Alternatives to the present methods include resistance welding of the molybdenum pin to the aluminum lead. However, resistance welding can create a joint that is difficult to qualify.

Although the description herein largely describes joining of a molybdenum piece to an aluminum piece, this is not intended to be so limited. This is merely one of many exemplary material combinations that can be joined using the presently-described method. As such, it is within the spirit and scope of the present invention that materials other than aluminum and molybdenum can be joined to form a component and/or using the method described herein.

Referring to <FIG>, in some examples, a component <NUM> is shown. In some examples, the component <NUM> is for use in an electrochemical cell, such as, for instance, a battery. In some examples, the component <NUM> can be used within a medical device. In further examples, the component <NUM> can be used within an implantable medical device. For instance, in various examples, the component <NUM> can be used within a pacemaker, a defibrillator, a cardiac monitor, a ventricular assist device, a drug delivery device, a neurostimulator, a deep brain stimulator, a cochlear implant, or a retinal implant, to name a few. However, this list of examples is not intended to be limiting. As such, in various examples, the component <NUM> can be used in other medical devices, implantable or external, not listed above. Moreover, in other examples, the component <NUM> can be used in non-medical devices.

In some examples, the component <NUM> includes a pin <NUM> including a pin diameter 120D and a pin length <NUM>. In some examples, the pin <NUM> includes a first end <NUM> and a second end <NUM>. The pin <NUM>, in some examples, includes a first material. In some examples, the first material of the pin <NUM> is molybdenum. In some examples, the pin <NUM> is formed entirely from the first material. In other examples, the pin <NUM> can be formed from the first material in addition to two or more other materials. In some examples, the pin <NUM> is a substantially cylindrical member having a longitudinal axis <NUM> along the pin length <NUM>. In some examples, the pin diameter 120D is relatively small. For instance, in some examples, the pin diameter 120D is substantially <NUM> inches. In other examples, the pin diameter 120D can be less than or greater than substantially <NUM> inches depending upon the application for which the component <NUM> is to be used. In other examples, the pin can include other shapes, including, but not limited to, flattened, square- or rectangle-shaped in cross section, triangle-shaped in cross section, ellipse-shaped in cross section, or the like.

The component <NUM>, in some examples, also includes a lead <NUM>. In some examples, the lead <NUM> is attached to the pin <NUM> to form the component <NUM>. In some examples, the lead <NUM> includes a lead width 140W (<FIG>), a lead thickness 140T, and a lead length <NUM> (<FIG>). The lead <NUM>, in some examples, includes a second material different from the first material of the pin <NUM>. In some examples, the second material of the lead <NUM> is aluminum. In some examples, the lead <NUM> is formed entirely from the second material. In other examples, the lead <NUM> can be formed from the second material in addition to two or more other materials. In some examples, the lead <NUM> is a substantially rectangular. In other examples, the lead can include shapes other than rectangular. In some examples, the lead thickness 140T is relatively small. For instance, in some examples, the lead thickness 140T is substantially <NUM> inches. In other examples, the lead thickness 140T can be less than or greater than substantially <NUM> inches depending upon the application for which the component <NUM> is to be used.

In some examples, the lead <NUM> and the pin <NUM> are at least partially overlapped with one another. The longitudinal axis <NUM> of the pin <NUM>, in some examples, is substantially aligned with a midline <NUM> of the lead <NUM> running the lead length <NUM>. This is not intended to be limiting, however, such that, in other situations, having the pin <NUM> oriented differently with respect to the lead <NUM> may be advantageous in certain applications. For instance, in other examples, the pin <NUM> can be aligned perpendicularly with respect to the midline <NUM> of the lead <NUM>. In still other examples, the pin <NUM> can be aligned with respect to the midline <NUM> of the lead <NUM> at an angle greater than zero degrees and less than ninety degrees.

At least a portion of the lead <NUM> that overlaps the pin <NUM> includes a channel <NUM> within the lead <NUM> in which at least a portion of the pin <NUM> sits or rests. The channel <NUM> includes a channel depth 150D, a channel length <NUM>, and a channel opening <NUM> defined at least partially by opposing first and second channel sides <NUM>, <NUM> extending the channel length <NUM>. The channel depth 150D is substantially equal to the pin diameter 120D of the pin <NUM>.

In some examples, the first end <NUM> of the pin <NUM> includes a rounded end <NUM>, for instance, to inhibit the first end <NUM> from piercing the lead <NUM>. With a rounded end <NUM>, in some examples, the lead <NUM> is less likely to be pierced or otherwise damaged by the pin <NUM>, for instance, if the lead <NUM> is bent with respect to the pin <NUM>. That said, in other examples, the first end <NUM> of the pin can include shapes other than rounded, such as, but not limited to, a flat end, a pointed end, or a concave end, to name a few.

In some examples, at least a first joint <NUM> is formed along at least a portion of the first channel side <NUM>. The first joint <NUM>, in some examples, includes the second material of the lead <NUM> deformed to at least partially close the channel opening <NUM> at the location of the first joint <NUM>, thereby retaining the pin <NUM> within the channel <NUM> of the lead <NUM> to attach the lead <NUM> to the pin <NUM>. In some examples, the first joint <NUM> continuously extends a distance, for instance, a first joint length <NUM>, along the first channel side <NUM>. In other examples, the first joint includes two or more discrete joints separated from one another along the first channel side <NUM>.

In some examples, the second material of the lead <NUM> is deformed by melting the first material at the first joint <NUM> to at least partially close the channel opening <NUM> at the location of the first joint <NUM>. In some examples, the second material of the lead <NUM> is melted at the first joint <NUM> by brazing. In further examples, the second material of the lead <NUM> is melted at the first joint <NUM> by laser brazing. In some examples, details about the laser brazing process can be similar to one or more of the examples of laser brazing processes that are described in <CIT>, <CIT>, entitled "CONNECTOR FROM THE TAB OF AN ELECTRODE CURRENT COLLECTOR TO THE TERMINAL PIN OF A FEEDTHROUGH IN AN ELECTROCHEMICAL CELL,". In other examples, the second material of the lead <NUM> can be melted at the first joint <NUM> in other ways, such as, but not limited to, one or more of using a torch, a furnace, induction, resistance, infrared, or the like. In some examples, the first joint <NUM> can be formed in a vacuum to decrease contaminants in the first joint <NUM>, improve thermal properties of the first joint <NUM>, and/or improve mechanical properties of the first joint <NUM>, for instance.

In some examples, a second joint <NUM> is formed along at least a portion of the second channel side <NUM>. The second joint <NUM>, in some examples, includes the second material of the lead <NUM> deformed to at least partially close the channel opening <NUM> at the location of the second joint <NUM>, thereby retaining the pin <NUM> within the channel <NUM> of the lead <NUM> to attach the lead <NUM> to the pin <NUM>. In some examples, the second joint <NUM> continuously extends a distance, for instance, a second joint length <NUM>, along the second channel side <NUM>. In other examples, the second joint includes two or more discrete joints separated from one another along the second channel side <NUM>. In some examples, the first joint <NUM> and the second joint <NUM> are disposed along the channel <NUM> at similar locations with respect to the pin <NUM>. In other examples, the first and second joints <NUM>, <NUM> can be staggered with respect to each other or otherwise disposed at different locations from one another along the channel <NUM>.

In some examples, the second material of the lead <NUM> is deformed by melting the first material at the second joint <NUM> to at least partially close the channel opening <NUM> at the location of the second joint <NUM>. In some examples, the second material of the lead <NUM> is melted at the second joint <NUM> by brazing. In further examples, the second material of the lead <NUM> is melted at the second joint <NUM> by laser brazing. In some examples, details about the laser brazing process can be similar to one or more of the examples of laser brazing processes that are described in <CIT>, <CIT>, entitled "CONNECTOR FROM THE TAB OF AN ELECTRODE CURRENT COLLECTOR TO THE TERMINAL PIN OF A FEEDTHROUGH IN AN ELECTROCHEMICAL CELL,". In other examples, the second material of the lead <NUM> can be melted at the second joint <NUM> in other ways, such as, but not limited to, one or more of using a torch, a furnace, induction, resistance, infrared, or the like. In some examples, the second joint <NUM> can be formed in a vacuum to decrease contaminants in the second joint <NUM>, improve thermal properties of the second joint <NUM>, and/or improve mechanical properties of the second joint <NUM>, for instance.

In some examples, by deforming the lead <NUM> around the pin <NUM> to form the channel <NUM> of the lead <NUM>, two contact areas are formed where the first and second channel sides <NUM>, <NUM> abut the pin <NUM>. These contact areas, in some examples, provide for consistent and ample contact between the pin <NUM> and the lead <NUM> to aid in the formation of relatively strong, reproducible, qualifiable first and second joints <NUM>, <NUM>.

After the first joint <NUM> is formed, a gap between the first joint <NUM> and the second channel side <NUM> is less than the diameter 120D of the pin <NUM>. In some examples, after the first joint <NUM> and the second joint <NUM> are formed, a gap between the first and second joints <NUM>, <NUM> is less than the diameter 120D of the pin <NUM>. In other examples, after the second joint <NUM> is formed, a gap between the second joint <NUM> and the first channel side <NUM> is less than the diameter 120D of the pin <NUM>. In various examples, such configurations further help to retain the pin <NUM> connected to the lead <NUM>.

In some examples, the second material is heated to a temperature at least slightly above a melting point of the second material, which allows the second material to flow or wet over the first material. When the second material cools, the first joint <NUM> and/or the second joint <NUM> is formed and the pin <NUM> and the lead <NUM> are joined together. In some examples, the second material of the lead <NUM> is substantially the only material that is melted. That is, little to none of the first material is melted in the process. In some examples, the melting point of the first material is higher than a melting point of the second material. In some examples, the first material is molybdenum, which has a melting point of substantially <NUM>,<NUM>° C, and the second material is aluminum, which has a melting point of substantially <NUM>° C. As such, by heating the pin <NUM> and the lead <NUM> to at least slightly above <NUM>° C (at standard pressure), but below <NUM>,<NUM>° C (at standard pressure), the aluminum of the lead <NUM> can flow over or wet the surface of the molybdenum of the pin <NUM> to join the pin <NUM> and the lead <NUM> upon cooling of the aluminum of the lead <NUM> to below the melting point of the aluminum of the lead <NUM>. Of course, in other examples, materials other than molybdenum and aluminum can be used for the first and second materials, respectively, in a manner similar to that which is described above, but the temperature to which the second material is heated would vary according to the first and second materials used to form the pin <NUM> and the lead <NUM>, respectively.

In this way, the present subject matter can be used to join two materials which are not generally considered compatible to join. For instance, in some examples, the present subject matter can be used to join materials that, when mixed, can form brittle intermetallics. This is because substantially only one of the two or more materials being joined melts, thereby inhibiting the likelihood that the two or more materials will mix. This is true in the example in which the first material is molybdenum and the second material is aluminum. Mixing of molybdenum and aluminum in an intermetallic pool often forms brittle intermetallics which can lead to the formation of a brittle joint between such materials. However, in the examples of the present subject matter, by melting substantially only the second material (aluminum, for instance), the issue of mixing of the first and second materials (for instance, molybdenum and aluminum, respectively, in some examples) is largely avoided, if not eliminated, thereby inhibiting the likelihood of forming brittle intermetallics and, in turn, a brittle joint.

In other examples, the second material of the lead <NUM> is deformed by crimping, pressing, or otherwise cold working the second material of the lead <NUM> to deform the second material of the lead <NUM> into the channel opening <NUM> to at least partially close the channel opening <NUM>. In still further examples, the pin <NUM> and the lead <NUM> can be joined using friction welding, resistance welding, or the like.

Referring to <FIG>, in some examples, a laser brazing apparatus <NUM> can be used to join together the pin <NUM> and the lead <NUM> to form the component <NUM>, as described herein. It is noted that, while the joining process is largely described herein using the laser brazing apparatus <NUM>, this is merely for ease in description. As such, it should be understood that other forms of apparatuses for accomplishing other types of joining (such as, but not limited to, the other forms of joined described herein) can be used to join the pin <NUM> and the lead <NUM> to form the component <NUM> and are, therefore, contemplated herein. The laser brazing apparatus <NUM>, in some examples, includes a base <NUM> configured to maintain the pin <NUM> and the lead <NUM> positioned for joining and a laser head <NUM> configured to impart energy (for instance, a laser beam 184A) to at least one of the pin <NUM> and the lead <NUM> in order to raise the temperature of at least one of the first and second materials in order to join the pin <NUM> and the lead <NUM>, as described herein. At least some aspects of the laser brazing apparatus <NUM> specific to the joining of the pin <NUM> and the lead <NUM> are described herein, but, for the sake of simplicity, not all details of the laser brazing apparatus <NUM> are described. As such, further details about a similar laser brazing apparatus are described in <CIT>, <CIT>, entitled "CONNECTOR FROM THE TAB OF AN ELECTRODE CURRENT COLLECTOR TO THE TERMINAL PIN OF A FEEDTHROUGH IN AN ELECTROCHEMICAL CELL,".

In some examples, the base <NUM> includes an opening <NUM> within which an insert block <NUM> can be placed. In some examples, the block <NUM> is formed from stainless steel. In some examples, the block <NUM> is machined to include features to aid in alignment and/or relative placement of the pin <NUM> and the lead <NUM> with respect to each other and/or with respect to the laser head <NUM> and/or the laser brazing apparatus <NUM>. In some examples, such features include a first recess <NUM> configured to accept and align the lead <NUM> with respect to the laser brazing apparatus <NUM>. A second recess <NUM>, in some examples, allows for placement of other pieces during laser brazing. In the example shown in <FIG>, the second recess <NUM> allows for placement of a header or lid <NUM> for a battery and an insulator <NUM>, each of which is attached to the pin <NUM> prior to joining of the pin <NUM> to the lead <NUM>. In some examples, the second recess <NUM> can be differently configured to accommodate pieces other than the header <NUM> and/or the insulator <NUM> depending on the component being made. In other examples, the second recess can be eliminated altogether, for instance, if no additional pieces are to be used to make the component.

In some examples, the block <NUM> includes a block groove <NUM> configured for placement of the pin <NUM> therein. In some examples, the base <NUM> can also or alternatively include a base groove <NUM> which is continuous with the block groove <NUM> of the block <NUM>, for instance, to facilitate placement of the pin <NUM> within the laser brazing apparatus <NUM> and/or to allow placement of a larger pin within the laser brazing apparatus <NUM>. The base <NUM>, in some examples, can include a recess <NUM> continuous with the first recess <NUM> of the block <NUM>, for instance, to facilitate placement of the lead <NUM> within the laser brazing apparatus <NUM> and/or to allow placement of a larger lead within the laser brazing apparatus <NUM>.

In some examples, the block <NUM> includes an opening <NUM> within which an insert <NUM> is placed. The insert <NUM>, in some examples, is disposed in a location with respect to the laser brazing apparatus <NUM> at which the laser brazing occurs. That is, the insert <NUM> is placed in the location most likely to be damaged by the laser head <NUM>. In this way, in some examples, the insert <NUM> can be replaced with another insert <NUM> should the first insert <NUM> become damaged, thereby decreasing the likelihood of damage to the block <NUM>, in turn reducing the likelihood (and expense) of replacing the block <NUM>. In some examples, the insert <NUM> includes an insert groove <NUM> configured to be continuous with the block groove <NUM> of the block <NUM> to facilitate placement of the pin <NUM> within the laser brazing apparatus <NUM>. In other examples, there need not be an opening and a removeable insert within the block. In such examples, the entire block could be replaced if the laser beam 184A damages the block.

The block <NUM>, in some examples, is removable and/or replaceable with the same block <NUM> or another block <NUM>. In some examples, the block <NUM> is removable so that the block <NUM> can be replaced with another similarly configured block <NUM>, for instance, if the first block <NUM> is damaged through normal wear and tear and/or if the laser beam 184A damages the block <NUM>. In other examples, the block <NUM> can be removed and another, differently configured block can be placed within the opening <NUM> of the base <NUM> to allow for a different component to be made (for instance, a component that is differently shaped, sized, or otherwise configured than the component <NUM> described herein). In other examples, the above-described features of the block <NUM> can be incorporated into the base, thereby eliminating the block altogether, such that the base itself is configured to align and position the pin <NUM> with respect to the lead <NUM> for joining of the pin <NUM> with the lead <NUM> to form the component <NUM>.

In some examples, the laser brazing apparatus <NUM> includes one or more holders <NUM>, <NUM> for securement of the pin <NUM> and/or the lead <NUM> during laser brazing. In some examples, a first holder <NUM> is selectively actuated to retain or release the first end <NUM> of the pin <NUM>. In some examples, a second holder <NUM> is selectively actuated to retain or release the lead <NUM>. In some examples, once the lead <NUM> and the pin <NUM> are properly placed within the laser brazing apparatus <NUM>, the first and second holders <NUM>, <NUM> can be actuated to retain the lead <NUM> and the pin <NUM> in position within the laser brazing apparatus <NUM> and/or in position with respect to one another. In some examples, once the pin <NUM> is joined to the lead <NUM> to form the component <NUM>, the first and second holders <NUM>, <NUM> can be released to remove the component <NUM> from the laser brazing apparatus <NUM>. In the example shown in <FIG>, the first and second holders <NUM>, <NUM> are actuated to retain or release the pin <NUM> and the lead <NUM> by rotation of first and second fasteners 188A, 189A, respectively. For instance, in some examples, rotation of the first fastener 188A and/or the second fastener 189A in a first direction causes tightening of the first holder <NUM> and/or the second holder <NUM>, respectively, to retain the pin <NUM> and/or the lead <NUM>. In further examples, rotation of the first fastener 188A and/or the second fastener 189A in a second direction causes loosening of the first holder <NUM> and/or the second holder <NUM>, respectively, to release the pin <NUM> and/or the lead <NUM>. Although fasteners 188A, 189A are described for actuation of the first and second holders <NUM>, <NUM>, this is not intended to be limiting. As such, it is contemplated herein that the first and second holders <NUM>, <NUM> can be actuated using actuators other than fasteners, such as, but not limited to pneumatic clamps, spring grips, or the like.

Referring now to <FIG>, and <FIG>, in some examples, a method of attaching the pin <NUM> to the lead <NUM> to form the component <NUM> is shown. In some examples, the pin <NUM> is aligned with the lead <NUM> so that at least a portion of the pin <NUM> overlaps at least a portion of the lead <NUM> (see <FIG>). In some examples, this is achieved by placing the lead <NUM> within the first recess <NUM> and the pin <NUM> within a portion of the block groove <NUM>. The longitudinal axis <NUM> of the pin <NUM>, in some examples, is substantially aligned with a midline <NUM> of the lead <NUM> running the lead length <NUM>. This is not intended to be limiting, however, such that, in other situations, having the pin <NUM> oriented differently with respect to the lead <NUM> may be advantageous in certain applications. In some examples, the first recess <NUM> and the block groove <NUM> of the laser brazing apparatus <NUM> facilitate alignment of the pin <NUM> and the lead <NUM> with one another and with respect to the laser brazing apparatus <NUM>.

Once the pin <NUM> is properly positioned with respect to the lead <NUM>, in some examples, the portion of the pin <NUM> overlapping the portion of the lead <NUM> is pressed into the lead <NUM> to form the channel <NUM> within the lead <NUM> (see <FIG>). In some examples, a force F is applied to the pin <NUM> to push the pin <NUM> against the lead <NUM> and deform the lead <NUM> into the block groove <NUM> of the laser brazing apparatus <NUM>, thereby forming the channel <NUM> in the lead <NUM>. In some examples, the force F is applied using a press. In some examples, the press is manually actuated using a lever once the pin <NUM> is in place with respect to the lead <NUM>. In other examples, the press is automatically actuated once the pin <NUM> is in place with respect to the lead <NUM>. For instance, in some examples, once the pin <NUM> is in place with respect to the lead <NUM>, the press can be actuated to move a foot <NUM> (see <FIG>) into contact with the pin <NUM> to apply the force F and push the pin <NUM> into the lead <NUM> and into the block groove <NUM> to form the channel <NUM> in the lead <NUM>. In other examples, the force F can be applied to the pin <NUM> and the lead <NUM> in other ways. For instance, in some examples, the pin <NUM> can be manually pushed into the block groove <NUM> using a digit of an operator. Once the pin <NUM> is pressed into the lead <NUM> and the block groove <NUM>, in some examples, the press and the foot <NUM> can be removed and the laser head <NUM> can be positioned over the base <NUM>. In other examples, the base <NUM> with the pin <NUM> and lead <NUM> disposed therein can be removed from under the foot <NUM> of the press and placed under the laser head <NUM>.

With the portion of the pin <NUM> disposed in place within the channel <NUM> of the lead <NUM>, in some examples, at least the first joint <NUM> is formed along at least a portion of the first channel side <NUM> (see <FIG> and <FIG>). In some examples, the first joint <NUM> includes the second material of the lead <NUM> deformed to at least partially close the channel opening <NUM> at the location of the first joint <NUM>, thereby retaining the pin <NUM> within the channel <NUM> of the lead <NUM> to attach the lead <NUM> to the pin <NUM>. In some examples, forming at least the first joint <NUM> includes melting the second material of the lead <NUM> at the first joint <NUM> to at least partially close the channel opening <NUM> at the location of the first joint <NUM>.

In some examples, the second joint <NUM> is formed along at least a portion of the second channel side <NUM> (see <FIG>). In some examples, the second joint <NUM> includes the second material of the lead <NUM> deformed to at least partially close the channel opening <NUM> at the location of the second joint <NUM>, thereby retaining the pin <NUM> within the channel <NUM> of the lead <NUM> to attach the lead <NUM> to the pin <NUM>. In some examples, forming the second joint includes melting the second material of the lead <NUM> at the second joint <NUM> to at least partially close the channel opening <NUM> at the location of the second joint <NUM>.

In some examples, melting of the second material of the lead <NUM> includes brazing. In further examples, forming of the first joint <NUM> and/or forming the second joint <NUM> include laser brazing. In some examples, with the pin <NUM> and the lead <NUM> properly positioned within the laser brazing apparatus <NUM>, the laser head <NUM> is aligned with respect to the pin <NUM> and the lead <NUM> and passed along the first channel side <NUM> and/or the second channel side <NUM> in order to form the first joint <NUM> and/or the second joint <NUM> at the desired locations. In some examples, the laser head <NUM> is moved and the base <NUM> of the laser brazing apparatus <NUM> is held stationary in order to pass the laser beam 184A along the first channel side <NUM> and/or the second channel side <NUM>. In other examples, the base <NUM> of the laser brazing apparatus <NUM> is moved and the laser head <NUM> is held stationary in order to pass the laser beam 184A along the first channel side <NUM> and/or the second channel side <NUM>.

Once the first joint <NUM> and/or the second joint <NUM> are formed, the completed component <NUM> can be removed from the laser brazing apparatus <NUM>. In some examples, the component <NUM> can be used in an electrochemical cell, such as, for instance, a battery. In some examples, the pin <NUM> of the component forms the feedthrough pin and positive terminal of the battery. In some examples, the lead <NUM> connects to a cathode or a cathode stack of the battery.

The present inventors have recognized various advantages of the subject matter described herein. The present inventors have recognized, among other things, that the present subject matter can be used to join pieces together, for instance, to form a component for use in various applications, such as, but not limited to, electrochemical cell components. In various examples, the present subject matter is advantageous in that it provides a method of joining pieces formed from materials that are substantially incompatible with other methods of joining. For instance, the present subject matter is advantageous because it provides a method of joining an aluminum piece to a molybdenum piece to form a relatively strong joint between the pieces. Also, the present subject matter is advantageous in that it provides for a consistent and/or qualifiable method of joining two pieces together. The present subject matter can be used to join pieces together even in the event that the pieces are formed from materials that are difficult to attach to one another using one or more other methods of attachment. While various advantages of the example systems are listed herein, this list is not considered to be complete, as further advantages may become apparent from the description and figures presented herein.

Although the subject matter of the present patent application has been described with reference to various examples, workers skilled in the art will recognize that changes can be made in form and detail without departing from the scope of the subject matter recited in the below claims.

The above Detailed Description includes references to the accompanying drawings, which form a part of the Detailed Description. The drawings show, by way of illustration, specific examples in which the present apparatuses and methods can be practiced.

The above Detailed Description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more elements thereof) can be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. Also, various features or elements can be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter can lie in less than all features of a particular disclosed embodiment. The scope of the invention should be determined with reference to the appended claims.

In this document, the terms "a" or "an" are used to include one or more than one, independent of any other instances or usages of "at least one" or "one or more. In this document, the terms "about" and "approximately" or similar are used to refer to an amount that is nearly, almost, or in the vicinity of being equal to a stated amount.

In the appended claims, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein. " Also, in the following claims, the terms "including" and "comprising" are open-ended, that is, an apparatus or method that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim.

Claim 1:
A component (<NUM>) for use in an electrochemical cell, the component (<NUM>) comprising:
a pin (<NUM>) including a pin diameter (120D) and a pin length (<NUM>), the pin (<NUM>) including a first material;
a lead (<NUM>) attached to the pin (<NUM>), the lead (<NUM>) including a lead width (140W), a lead thickness (140T), and a lead length (<NUM>), the lead (<NUM>) including a second material different from the first material of the pin (<NUM>), wherein the lead (<NUM>) and the pin (<NUM>) are at least partially overlapped with one another, wherein at least a portion of the lead (<NUM>) that overlaps the pin (<NUM>) includes a channel (<NUM>) within the lead (<NUM>) in which at least a portion of the pin (<NUM>) sits, the channel (<NUM>) including a channel depth (150D), a channel length (<NUM>), and a channel opening (<NUM>) defined at least partially by opposing first and second channel sides (<NUM>, <NUM>) extending the channel length (<NUM>), wherein the channel depth (150D) is substantially equal to the pin diameter (120D) of the pin (<NUM>); and
at least a first joint (<NUM>) formed along at least a portion of the first channel side (<NUM>), wherein the first joint (<NUM>) includes the second material of the lead (<NUM>) deformed to at least partially close the channel opening (<NUM>) at the location of the first joint (<NUM>) such that a gap between the first joint (<NUM>) and the second channel side (<NUM>) is formed, the gap being less than the pin diameter (120D) of the pin (<NUM>), thereby retaining the pin (<NUM>) within the channel (<NUM>) of the lead (<NUM>) to attach the lead (<NUM>) to the pin (<NUM>).