Conductive Adhesive Battery Cell Contact Design

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Solution Overview

Problem

Existing rechargeable batteries face challenges with complex and costly cable harnesses, risk of short circuits during welding, heat sensitivity of Li-ion cells, and poor connections due to dirt and corrosion with plug-in connectors.

Innovation Solution

A rechargeable battery design using an electrically conductive adhesive to connect at least one battery cell to an electronic component via a contact element, with the contact element connected to a cell connector, and optionally arranged on a carrier foil for flexible conductor paths, simplifying assembly and preventing incorrect connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If prebuilt cable harnesses with electrical lines fixed at cell connectors are used, then electrical connection is established, but the cable harness becomes difficult and complicated to handle during welding process

Engineering Contradiction:

Improveelectrical connectionVSAvoidhandling during welding

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent divides the connection system into separate components: cell connectors are welded to battery cells first, then electrical lines with contact elements are connected to cell connectors separately via electrically conductive adhesive. This segmentation eliminates the complexity of handling prebuilt cable harnesses during welding while ensuring reliable electrical connection.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If electrical lines are connected to cell connectors after welding, then handling during welding is simplified, but risk of short circuit from undesired contacting increases

Engineering Contradiction:

Improvehandling during weldingVSAvoidshort circuit risk

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent introduces cell connectors as intermediary components between battery cells and electrical lines. The cell connectors are welded to battery cells first in a controlled manner, then electrical lines are connected to cell connectors using electrically conductive adhesive. This intermediary approach allows separate, controlled connection steps that reduce short circuit risk while maintaining ease of operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If soldering joint is used to connect electrical lines after welding, then electrical connection is established, but heat can damage rechargeable battery cells

Engineering Contradiction:

Improveelectrical connectionVSAvoidheat damage to cells

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal soldering process with a mechanical bonding method using electrically conductive adhesive. The adhesive forms electrically conductive joints between electrical lines and cell connectors without requiring high heat, thereby establishing reliable electrical connection while avoiding heat damage to temperature-sensitive rechargeable battery cells.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If plug-in connectors are used to connect electrical lines, then assembly is simplified, but manufacturing cost and space requirements increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidconnector complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent uses electrically conductive adhesive as a composite material that combines the functions of mechanical bonding and electrical conduction in a single component. This eliminates the need for separate mechanical connectors and conductive paths, simplifying the overall structure while maintaining assembly simplicity and reducing manufacturing cost and space requirements.

Inventive Principle:

Principle #40Composite materials

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 provides a secure, stable, and cost-effective connection between battery cells and electronic components, reducing the risk of short circuits and heat damage while maintaining electrical integrity.

Implementation Method 1

The contact element is connected in an electrically conductive way with the cell connector via electrically conductive adhesive

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

connected in an electrically conductive way via electrically conductive adhesive

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8869913B2Making electrical contact with a rechargeable battery having a plurality of rechargeable battery cells

Publication Date: 2014.10.28 ROBERT BOSCH GMBH

AI summary

In a rechargeable battery having a plurality of rechargeable battery cells, wherein at least one rechargeable battery cell is connected to an electronic component, which is associated with the rechargeable battery, via an electrical line, the electrical line has at least one contact element which is electrically conductively connected to the at least one rechargeable battery cell by an electrically conductive adhesive.