Mechanical and electrical properties of metal-carbon connections for battery applications

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Material selection and processing techniques were investigated to form carbon-metal bonds. Mechanical and electrical characterization was performed to more fully comprehend the bonding mechanisms and properties. Utilizing carbon fibers as a primary conduction medium, the specimens from the processes investigated were utilized with lithium-ion cells to further characterize the electrical performance. Electroplating nickel onto the ends of the carbon fibers provides a relatively simple processing technique which improves fiber adhesion to nickel tabs by over 4.7 times when compared to conductive silver epoxy and over 5 times greater than a 1 inch immersion of carbon fiber into a SAC305 solder ingot. Additionally, a reduction of electrical resistance by 0.7 times over the solder ingot is achieved with the electroplating technique. The results of the electroplating are achieved by using about 25% less available contact area than the solder ingot and are scalable for usage in electrical circuits.