Battery Cell to Connecting Bar Coupling via Welding and Anisotropic Film
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Solution Overview
Problem
The existing connective structure between battery cells and connecting bars in battery packs lacks sufficient coupling force, which can lead to reliability issues such as reduced durability and performance under vibrations and shocks.
Innovation Solution
A connective structure that includes a welding region between the battery cell and the connecting bar, with an anisotropic conductive film and a welding reinforcement portion, such as a double-sided adhesive tape, to enhance the mechanical and electrical connection, using materials like nickel, steel, and gold, and a design with planar and sloping portions to improve the bonding area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If only welding is used to connect the battery cell and connecting bar, then the connection is simple and fast, but the coupling force is insufficient under vibrations and shocks
Solution Approach 1:
The patent combines welding and adhesive bonding into a hybrid connection structure. The welding region provides initial strong bonding while the anisotropic conductive film and welding reinforcement portion add additional bonding mechanisms, creating a multi-layered connection that resists vibrations and shocks better than welding alone.
Solution Approach 2:
The connection structure uses composite materials including metal welding zones, anisotropic conductive film with conductive particles in a polymer matrix, and welding reinforcement portions. This composite approach combines the high strength of metal bonding with the vibration-resistant properties of adhesive bonding.
2Strength
If the connection area is increased to improve coupling force, then the bonding strength improves, but the manufacturing complexity and time increase
Solution Approach 1:
The connection structure is segmented into distinct functional zones: a welding region for primary bonding, an anisotropic conductive film region for electrical and mechanical connection, and welding reinforcement portions for additional strength. This segmentation allows each zone to be optimized independently and facilitates automated manufacturing processes.
Solution Approach 2:
The anisotropic conductive film is pre-applied to the connecting bar before welding, and the welding reinforcement portions are positioned in advance. This preliminary preparation enables faster assembly and reduces manufacturing complexity by organizing the bonding process into predetermined steps.
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 solution significantly enhances the coupling force between the battery cell and the connecting bar, improving the reliability, vibration resistance, and shock resistance of the battery pack, making it more durable and efficient.
Implementation Method 1
an anisotropic conductive film formed at the outer periphery of the welding region and connecting the battery cell and the connecting bar to each other
Implementation Method 2
a welding region formed at a connecting area of the battery cell and the connecting bar
Implementation Method 3
The welding reinforcement portion may be an insulating adhesive. The welding reinforcement portion may be a double-sided adhesive tape.
Data Source
AI summary
A battery pack having an improved a coupling force between a battery cell and a connecting bar of a connecting structure. The connecting structure includes at least one battery cell, a connecting bar electrically connected to the battery cell, a welding region formed at a connecting area of the battery cell and the connecting bar, and an anisotropic conductive film formed at the outer periphery of the welding region and connecting the battery cell and the connecting bar to each other.