Replaceable Conductive Adhesive Connection for Battery Contact Pads
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Solution Overview
Problem
Current connection systems for battery management systems, such as wired connectors, are costly, space-consuming, and difficult to automate, and permanent connection methods like welding or soldering compromise serviceability.
Innovation Solution
A replaceable electrical connection system using a conductive core with an electrically conductive adhesive, allowing for a cost-effective, simple, and automated installation method that improves serviceability by using materials like copper or aluminum foils and conductive inks, with flexible insulation and adhesive layers for secure and efficient signal transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired connectors with clamping/locking mechanisms are used, then reliable electrical connection is achieved, but cost increases and space consumption increases
Solution Approach 1:
The patent extracts the essential function of electrical connection from complex connector assemblies and implements it through a simple conductive adhesive layer applied directly to the contact surface, eliminating clamping and locking mechanisms while maintaining reliable electrical contact
Solution Approach 2:
The patent replaces mechanical connection systems (clamps, locks, screws) with a chemical/adhesive-based system where conductive adhesive provides both mechanical attachment and electrical conduction, thereby reducing device complexity and space requirements
2Reliability
If wired connectors with clamping/locking mechanisms are used, then reliable electrical connection is achieved, but installation automation becomes difficult
Solution Approach 1:
The conductive adhesive system is self-applying through dispensing or printing processes, requiring no manual assembly of multiple connector components, which enables straightforward automation of the installation process while maintaining reliable electrical connections
3Stability of the object's composition
If permanent connection methods like welding or soldering are used, then connection stability is improved, but serviceability deteriorates
Solution Approach 1:
The patent creates a dynamically adjustable connection system where the adhesive bond strength can be tailored to allow for controlled removal and replacement, providing both stability during operation and ease of service when needed, unlike permanent welding or soldering connections
4Device complexity
If conductive adhesive is used, then cost is reduced and space is reduced, but connection strength may be compromised
Solution Approach 1:
The patent employs composite material structures combining the conductive adhesive with reinforcing elements or optimized substrate designs to achieve both mechanical strength and electrical conductivity, overcoming the limitation of simple adhesive applications
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 solution reduces costs and space requirements while enabling automated installation and enhanced serviceability, allowing for efficient signal transfer and easy replacement of connections in battery management systems.
Implementation Method 1
an electrically conductive adhesive provided on the contact surface for connecting with the contact pad
Data Source
Figure 1~2A
Figure 2B~3
Figure 4~5
AI summary
A connection system for providing a replaceable electrical connection to a contact pad of an electrical component. The system includes an electrical conductor having a conductive core with a body section and at least a first end section. The conductive core is electrically insulated except for the end section which has a contact surface for electrical connection with the contact pad. An electrically conductive adhesive is provided on the contact surface for connecting with the contact pad. The connection can be exchanged by cutting away the body section of an existing connection and applying a new connection onto or adjacent to the existing installed end section.