Battery Module Terminal Bonding With Conductive and Insulative Adhesives
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Solution Overview
Problem
Existing battery modules face challenges in effectively and reliably joining positive and negative terminals for both electrical and mechanical connections, lacking a robust and efficient method that does not involve welding.
Innovation Solution
The use of a first electrically conductive adhesive material and a second electrically isolative adhesive material to weldlessly connect and isolate terminals of electrochemical cells through interconnect boards, providing both electrical conductivity and mechanical stability without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to join terminals, then electrical connection reliability is improved, but manufacturing complexity and safety risks increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with an adhesive bonding process (chemical/mechanical system). The adhesive material forms both mechanical bonds and electrical connections between terminals and interconnect boards, eliminating the need for welding equipment and complex welding procedures while maintaining connection reliability.
Solution Approach 2:
The patent changes the bonding mechanism from high-temperature welding to room-temperature or low-temperature adhesive bonding. This parameter change in bonding temperature and method simplifies the manufacturing process, reduces equipment requirements, and eliminates safety risks associated with welding operations.
2Strength
If welding is used to join terminals, then mechanical strength is improved, but manufacturing cost and safety risks increase
Solution Approach 1:
The adhesive bonding process replaces welding to provide mechanical strength through chemical adhesion and mechanical interlocking. The adhesive material is designed to achieve bond strengths comparable to welding while being easier to apply and requiring less specialized equipment and training.
Solution Approach 2:
The adhesive materials used are cost-effective alternatives to welding consumables. The bonding process uses inexpensive adhesive materials that can be applied directly without expensive welding equipment, reducing overall manufacturing costs.
3Reliability
If conductive adhesive material is used, then electrical conductivity is improved, but electrical isolation between adjacent terminals deteriorates
Solution Approach 1:
The patent applies different adhesive materials with different electrical properties to different locations. Conductive adhesive material is used only where electrical connection is needed (between terminals and interconnect boards), while electrically isolative adhesive material is used in adjacent areas where isolation is required. This local differentiation of material properties solves both requirements simultaneously.
Solution Approach 2:
The bonding process is segmented into distinct zones: conductive adhesive zones for electrical connections and isolative adhesive zones for electrical separation. This spatial segmentation of adhesive functions ensures that conductivity and isolation requirements are both met without interference.
4Ease of manufacture
If weldless joining is used, then manufacturing safety is improved, but connection reliability may deteriorate
Solution Approach 1:
The patent uses composite adhesive materials that combine multiple functions: electrical conductivity, mechanical bonding strength, and environmental resistance. These composite materials achieve connection reliability comparable to welding while maintaining the safety advantages of weldless joining. The adhesive formulation integrates conductive fillers, bonding agents, and protective components into a single material system.
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 approach enhances the mechanical connections and stress relief at junctions, improving the reliability and manufacturability of battery modules while reducing the risk of in-use faults.
Implementation Method 1
a first adhesive material. A first set of the positive and negative terminals of the plurality of electrochemical cells are electrically connected and weldlessly mechanically joined via a first set of the ICBs employing the first adhesive material
Implementation Method 2
a second adhesive material, wherein selected portions of the plurality of ICBs are weldlessly mechanically joined to adjacent portions of the electrochemical cells via the second adhesive material
Data Source
AI summary
A battery module composed of a plurality of electrochemical cells has selected positive and negative terminals being electrically connected and weldlessly mechanically joined employing a first adhesive material having electrically conductive properties and a second adhesive material having electrically isolative properties.