Battery Module Assembly Using Conductive Adhesive Terminal Pads

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Solution Overview

Problem

Existing battery modules face challenges in efficiently and reliably mechanically and electrically joining electrochemical cells without the drawbacks of welding, such as burn-throughs and galvanic corrosion.

Innovation Solution

The use of a malleable curable conductive adhesive material to weldlessly connect and join the positive and negative terminals to the electrode stack, forming conductive adhesive pads on end caps and enclosures to establish electrical connections without welding, allowing for direct assembly of the electrode stack into the enclosure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to join terminals to electrode stack, then mechanical and electrical connection is achieved, but burn-throughs and galvanic corrosion occur

Engineering Contradiction:

Improveconnection reliabilityVSAvoidburn-through and galvanic corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using fasteners that physically secure the terminals to the electrode stack without generating heat or causing galvanic corrosion. This substitution eliminates the harmful effects of welding while maintaining reliable electrical and mechanical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary component (fastener) between the terminal and the electrode stack that provides both mechanical attachment and electrical conductivity. This intermediary enables reliable connection without direct welding contact, thereby preventing burn-through and galvanic corrosion issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If soldering or welding is used to attach terminals, then electrical connection is established, but manufacturing complexity and welding-related risks increase

Engineering Contradiction:

Improveassembly easeVSAvoidjoining process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces complex welding and soldering processes with simpler mechanical fastening operations. The fastening process using pre-configured fasteners is easier to manufacture and assemble, reducing both manufacturing complexity and welding-related risks while establishing reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If traditional welding processes are used, then strong mechanical attachment is achieved, but electrolysis and galvanic corrosion are minimized only partially

Engineering Contradiction:

Improvemechanical attachment strengthVSAvoidelectrolysis and galvanic corrosion

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent replaces welding (which creates strong mechanical bonds but causes galvanic corrosion) with mechanical fastening that provides adequate attachment strength without the harmful electrochemical effects. The fastener system maintains mechanical strength while eliminating the conditions that cause electrolysis and galvanic corrosion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs fasteners that can be simpler and potentially disposable components, replacing complex welding operations. These fastening components provide sufficient mechanical strength for the application while being easier to manufacture and install, reducing overall system complexity and harmful effects.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 method reduces manufacturing complexity, eliminates welding-related risks, and facilitates reliable electrical and mechanical connections while minimizing electrolysis and galvanic corrosion, enabling efficient assembly of battery modules.

Implementation Method 1

employing an electrically conductive mechanically adhesive material

Methodology Applied

Scientific EffectAdhesive: Adhesive

Implementation Method 2

electrically conductive mechanically adhesive material

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS12418080B2Electrochemical battery module and method therefor

Publication Date: 2025.09.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for assembling a battery cell includes assembling an electrode stack that includes first electrodes, second electrodes, and separators. A first conductive adhesive pad is formed on an end cap, wherein the first conductive adhesive pad electrically couples to a first terminal arranged on the end cap. A second conductive adhesive pad is formed on an enclosure, wherein the second conductive adhesive pad electrically couples to a second terminal arranged on the enclosure. The end cap is installed onto the electrode stack with the first cell tabs engaging the first conductive adhesive pad. The electrode stack is inserted into the enclosure such that the plurality of the second cell tabs engages the second conductive adhesive pad. The end cap is assembled onto the enclosure.