Electrode Tab Bonding Layout for Reliable Battery Pack Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face challenges in maintaining a seamless electrical connection between the electrode tab and the circuit portion, leading to increased resistance and reduced output due to inadequate accommodation of insulating resin and conductive particles, which can result in decreased battery capacity and reliability.
Innovation Solution
A battery pack design incorporating a conductive thermocompression bonding layer with conductive particles and insulating resin, where the electrode tab features alternating strips and accommodation spaces to optimize the distribution and discharge of insulating resin, and burrs along the contour line to enhance conductive particle density, ensuring a reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional bonding layer structure is used, then the manufacturing process is simple, but the electrical connection reliability is poor due to inadequate accommodation of insulating resin and conductive particles
Solution Approach 1:
The electrode tab is divided into multiple functional regions: solid portions for electrical connection and accommodation spaces for housing insulating resin. This segmentation allows the bonding layer to have differentiated functional zones that improve electrical connection reliability while maintaining manufacturing feasibility through standardized processes.
Solution Approach 2:
Different regions of the bonding layer are designed with different properties: regions over solid portions have high conductive particle density for electrical connection, while regions over accommodation spaces have high insulating resin density for isolation. This local differentiation optimizes both reliability and electrical performance without requiring complete structural redesign.
2Power
If the bonding layer has uniform distribution of conductive particles and insulating resin, then the manufacturing process is simple, but the electrical connection resistance is high and output is reduced
Solution Approach 1:
The bonding layer is designed with spatially varying composition: conductive particles are concentrated in regions corresponding to solid portions for low-resistance electrical connection, while insulating resin is concentrated in regions corresponding to accommodation spaces. This local quality variation increases battery output by reducing connection resistance while using standard lamination processes.
Solution Approach 2:
Accommodation spaces are pre-formed in the electrode tab before bonding layer application. This preliminary structuring guides the subsequent lamination process to automatically achieve the desired non-uniform distribution of conductive particles and insulating resin, simplifying manufacturing while improving power output.
3Reliability
If insulating resin is not properly accommodated, then the bonding process is faster, but electrical connection reliability decreases due to poor insulation and increased resistance
Solution Approach 1:
Accommodation spaces are pre-formed in the electrode tab structure before bonding layer application. This preliminary action provides predetermined housing for insulating resin, ensuring proper insulation during the bonding process without requiring extended processing time or additional steps.
Solution Approach 2:
The bonding layer is segmented into regions with different functional compositions: insulating resin is directed to accommodation spaces for isolation functions, while conductive particles are directed to solid portions for conduction. This segmentation achieves both insulation and conduction requirements in a single bonding operation, improving reliability without time loss.
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 the electrical connection reliability and output of the battery pack by maintaining a high density of conductive particles and efficiently discharging insulating resin, thereby improving the battery's capacity and performance.
Implementation Method 1
a conductive thermocompression bonding layer, the conductive thermocompression bonding layer conductively connecting the electrode tab and the circuit portion
Implementation Method 2
a conductive thermocompression bonding layer, the conductive thermocompression bonding layer conductively connecting the electrode tab and the circuit portion
Data Source
AI summary
A battery pack includes a battery cell including an electrode tab drawn out therefrom; a circuit portion electrically connected to the electrode tab; and a conductive thermocompression bonding layer, the conductive thermocompression bonding layer conductively connecting the electrode tab and the circuit portion, and including conductive particles and an insulating resin accommodating the conductive particles, wherein the electrode tab includes at least one accommodation space accommodating the insulating resin therein.