Battery Pack Bonding Structure for Low-Resistance Cell Connections

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Solution Overview

Problem

Existing battery connections face challenges in achieving efficient and reliable electrical conductivity while preventing short circuits and resistance increases due to the interaction of conductive materials and insulating resins in conventional bonding methods.

Innovation Solution

A battery pack design incorporating a conductive thermocompression bonding layer with a conductive pad layer featuring alternating convex and concave patterns, which supports conductive particles and accommodates insulating resin, ensuring smooth electrical connection and preventing interference, thereby reducing resistance and short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional bonding method using conductive materials and insulating resins is used, then electrical connection is achieved, but connection resistance increases and reliability decreases due to interference between conductive materials and insulating resins

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection resistance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The bonding layer is segmented into distinct convex portions (conductive material only) and concave portions (insulating resin only), eliminating the interference between conductive materials and insulating resins that occurs in conventional mixed-structure bonding layers. This segmentation allows each material to perform its function without interfering with the other, reducing connection resistance and improving reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the bonding layer are assigned different local qualities: convex portions contain only conductive materials optimized for electrical conduction, while concave portions contain only insulating resins optimized for electrical insulation. This local differentiation ensures that conductive and insulating functions are performed by specialized regions rather than by mixed materials interfering with each other.

Inventive Principle:

Principle #3Local quality

2Reliability

If conductive materials and insulating resins are mixed in the bonding layer, then both conductivity and insulation are provided, but the interaction between materials causes resistance increase and potential short circuits

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidshort circuit risk and resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bonding layer is divided into spatially separated convex portions (conductive) and concave portions (insulating), preventing the harmful interaction between conductive materials and insulating resins that occurs when they are mixed in the same region. This segmentation eliminates the risk of short circuits and resistance increases caused by material interference.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The convex and concave structures act as intermediaries that separate the conductive and insulating materials in space, allowing both materials to coexist in the bonding layer without direct contact or interference. This structural mediation prevents the harmful effects of material interaction while maintaining both conductivity and insulation functions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a flat bonding layer structure is used, then manufacturing is simple, but electrical conductivity and insulation performance are compromised due to material interference

Engineering Contradiction:

Improveelectrical connection performanceVSAvoidbonding layer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bonding layer incorporates convex (protruding) and concave (recessed) curved structures instead of a flat surface. The convex portions provide concentrated conductive contact points, while the concave portions provide insulated regions. This curved geometry improves electrical connection performance without significantly complicating the manufacturing process, as the convex-concave pattern can be formed through standard patterning techniques.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

The design enhances electrical conductivity and reduces connection resistance by providing a differentiated support for conductive particles and insulating resin, ensuring stable and efficient power transfer between battery cells and circuit components.

Implementation Method 1

a conductive thermocompression bonding layer and a conductive pad layer

Methodology Applied

Scientific EffectThermocompression bonding:

Data Source

PatentUS12412934B2Battery pack

Publication Date: 2025.09.09 SAMSUNG SDI CO LTD

AI summary

A battery pack is provided. The battery pack includes a battery cell including an electrode extending in a first direction, a circuit portion connected to the electrode of the battery cell, and a connection portion forming a connection between the electrode of the battery cell and the circuit portion, the connection portion including a conductive thermocompression bonding layer and a conductive pad layer having a concave accommodation space formed in a second direction intersecting with the first direction to accommodate a portion of the conductive thermocompression bonding layer.