Battery Pack Tab Connection Using Intaglio ACF Crimping
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Solution Overview
Problem
Existing battery packs face challenges in securing stable electrical connections and resistance due to difficulties in ensuring a flat crimping surface when using anisotropic conductive films with thin, hard materials for connecting protective circuit modules to electrode tabs.
Innovation Solution
The battery pack design incorporates an anisotropic conductive film with conductive balls, an insulation plate, and a penetration part on the circuit board's intaglio area, allowing for stable electrical connections and resistance by ensuring the conductive balls align correctly even with non-flat surfaces, using an insulation plate and anisotropic conductive film to connect electrode tabs to the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an anisotropic conductive film is used to connect the protective circuit module to the electrode tabs, then electrical connection is achieved, but stable resistance cannot be secured due to non-flat crimping surfaces
Solution Approach 1:
The circuit board is designed with an intaglio (concave) portion at the specific location where the electrode tab is connected. This local structural modification creates a flat crimping surface within the concave area, ensuring uniform compression and stable electrical resistance only where needed, while the rest of the board maintains its original structure.
Solution Approach 2:
The anisotropic conductive film serves as an intermediary material between the electrode tab and the circuit board. It contains conductive particles that can deform and fill gaps, enabling reliable electrical connection even when there are slight surface irregularities, thus mediating between the non-flat board surface and the requiring-flat-surface connection need.
2Length of stationary object
If thin and hard materials are used for the circuit board, then device thickness is reduced, but flat crimping surface cannot be ensured
Solution Approach 1:
Instead of making the entire circuit board thick to ensure flatness, the invention applies local quality by creating an intaglio (concave) portion only at the connection area. This allows the overall board to remain thin while providing a localized flat surface for reliable crimping, solving the contradiction between thinness and flatness.
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 achieves stable resistance and electrical connections by minimizing resistance distribution due to height imbalances and improving adhesion, even with non-uniform compressed surfaces, ensuring reliable operation of the battery pack.
Implementation Method 1
an anisotropic conductive film disposed between the insulation plate and the circuit board and including a plurality of conductive balls
Data Source
AI summary
A battery pack is proposed. The battery pack may include an electrode assembly and a protective circuit module including a circuit board having an intaglio electrically connected to a conductive pattern formed on a plate surface, and a tab connector electrically connected to a first electrode tab and a second electrode tab, respectively. The tab connector is electrically connected to the circuit board on the intaglio. When the electrode tabs and the tab connector are brought into contact with an anisotropic conductive film, conduction of conductive balls can be made at the intaglio of the tab connector. Therefore, even if the compressed surface is non-uniform, stable resistance and electrical connection can be provided by minimizing resistance distribution due to height imbalance of the anisotropic conductive film.