阅读说明：本技术 带有附接的系统模块的电池组 (Battery pack with attached system module ) 是由 H·巴拉拉姆 N·J·博尼 汪澎川 于 2020-07-27 设计创作，主要内容包括：本公开涉及带有附接的系统模块的电池组。根据本技术的实施方案的电池系统可包括电池。电池可包括能够沿着电池的第一表面触及的第一电极端子和第二电极端子。系统可包括与电池电耦接的模块。模块可包括电路板,该电路板通过第一表面和与第一表面相对的第二表面来表征。模块可包括从电路板的第一表面朝向电池延伸的模具。模块可包括将模块与第一电极端子电耦接的第一导电接片。模块可包括将模块与第二电极端子电耦接的第二导电接片。第二导电接片可基本上平行于电路板的第一表面延伸跨过模具。(The present disclosure relates to a battery pack with attached system modules. A battery system according to embodiments of the present technology may include a battery. The battery may include a first electrode terminal and a second electrode terminal accessible along a first surface of the battery. The system may include a module electrically coupled to the battery. The module may include a circuit board characterized by a first surface and a second surface opposite the first surface. The module may include a mold extending from the first surface of the circuit board toward the battery. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The module may include a second conductive tab electrically coupling the module with the second electrode terminal. The second conductive tab may extend across the die substantially parallel to the first surface of the circuit board.)

1. A battery system, comprising:

a battery, wherein the battery comprises a first electrode terminal and a second electrode terminal accessible along a first surface of the battery; and

a module electrically coupled to the battery, the module comprising:

a circuit board characterized by a first surface and a second surface opposite the first surface;

a mold extending from the first surface of the circuit board toward the battery,

a first conductive tab electrically coupling the module with the first electrode terminal, an

A second conductive tab electrically coupling the module with the second electrode terminal, wherein the second conductive tab extends across the mold substantially parallel to the first surface of the circuit board.

2. The battery system of claim 1, wherein the battery further comprises a port positioned proximate a lateral edge of the first surface of the battery, wherein the second conductive tab extends between the mold and the port.

3. The battery system of claim 2, further comprising a first adhesive positioned between the second conductive tab and the mold proximate the port.

4. The battery system of claim 1, wherein the first conductive tab extends beyond a first lateral edge of the module, wherein the second conductive tab extends beyond a second lateral edge of the module opposite the first lateral edge of the module, and wherein the first and second conductive tabs extend from the second surface of the module.

5. The battery system of claim 4, wherein the second conductive tab extends around the second lateral edge of the module and is wound on the mold toward the second electrode terminal.

6. The battery system of claim 4, wherein the first electrode terminal extends out of the first surface of the battery toward the first surface of the circuit board, and wherein the first conductive tab extends past a plane of the second surface of the circuit board to couple with the first electrode terminal.

7. The battery system of claim 1, wherein an electronic device extends from the first surface of the circuit board toward the battery.

8. The battery system of claim 1, wherein the circuit board extends substantially parallel to the first surface of the battery to a position proximate the first electrode terminal.

9. The battery system of claim 1, further comprising an adhesive extending across the module, and wherein a first end of the adhesive and a second end of the adhesive are coupled with the battery.

10. The battery system of claim 9, wherein the adhesive comprises an insulator along a portion of the adhesive, and wherein the insulator extends from a first end of the adhesive across the first electrode terminal.

11. The battery system of any of claims 1-10, further comprising a flexible coupling extending from the module and including a board-to-board connector at a distal end of the flexible coupling.

12. A battery system, comprising:

a battery characterized by a first surface, a second surface, and a third surface, wherein the second surface and the third surface are substantially parallel to each other, wherein the first surface of the battery extends between the second surface and the third surface, and wherein the first surface comprises a first electrode terminal and a second electrode terminal;

a module coupled with the first surface of the battery and comprising a circuit board characterized by a first surface and a second surface opposite the first surface, wherein the module comprises:

a mold extending from the first surface of the circuit board toward the battery,

a first conductive tab extending from the second surface of the circuit board to the first electrode terminal, an

A second conductive tab extending from the second surface of the circuit board to the second electrode terminal; and

a flexible coupling extending from the second surface of the circuit board.

13. The battery system of claim 12, wherein the mold extends laterally parallel to the first surface of the battery, wherein the first electrode terminal of the battery extends from the first surface of the battery, and wherein the mold is retained between the first electrode terminal of the battery and a lateral edge of the battery.

14. The battery system of claim 12, wherein the second conductive tab extends around a lateral edge of the module and is wound on the mold toward the second electrode terminal.

15. The battery system of claim 14, wherein the second conductive tab is coupled to the mold by a first adhesive, and wherein the second conductive tab is coupled to the battery by a second adhesive.

16. The battery system of claim 12, wherein the second surface of the battery comprises a flange extending out of an intersection of the first surface of the battery and the second surface of the battery, and wherein the circuit board of the module extends substantially parallel to the first surface of the battery between the flange and the third surface of the battery.

17. The battery system of claim 12, wherein the module extends across the second electrode terminal of the battery.

18. The battery system of claim 12, wherein the circuit board comprises a test point accessible on the second surface of the circuit board.

19. The battery system of any of claims 12-18, wherein the flexible coupling comprises a connector at a distal end of the flexible coupling, and wherein the flexible coupling is coupled with the second surface of the circuit board at a proximal end of the flexible coupling.

20. A battery system, comprising:

a battery, wherein the battery comprises a first electrode terminal, a second electrode terminal, and a port accessible along a first surface of the battery;

a module electrically coupled to the battery, the module comprising:

a mold extending toward the battery, wherein the mold extends across the second electrode terminal and the port between the first electrode terminal and a lateral edge of the battery,

a first conductive tab electrically coupling the module with the first electrode terminal, an

A second conductive tab electrically coupling the module with the second electrode terminal, wherein the second conductive tab extends from a surface of the module opposite the mold, and wherein the second conductive tab extends across the mold around a lateral edge of the module and between the mold and the battery;

a flexible coupling extending from the module from a surface of the module opposite the mold; and

an adhesive positioned between the mold and the second conductive tab.

Technical Field

The present technology relates to a battery system. More particularly, the present technology relates to battery component configurations incorporating modules with batteries.

Background

Batteries are used in many devices. As the size of the device housing the battery decreases, the available space for battery cells and associated system materials may limit placement options.

Disclosure of Invention

A battery system according to embodiments of the present technology may include a battery. The battery may include a first electrode terminal and a second electrode terminal accessible along a first surface of the battery. The system may include a module electrically coupled to the battery. The module may include a circuit board characterized by a first surface and a second surface opposite the first surface. The module may include a mold extending from the first surface of the circuit board toward the battery. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The module may include a second conductive tab electrically coupling the module with the second electrode terminal. The second conductive tab may extend across the die substantially parallel to the first surface of the circuit board.

In some embodiments, the battery may include a port positioned proximate a lateral edge of the first surface of the battery. A second conductive tab may extend between the die and the port. The system can include a first adhesive positioned between the second conductive tab and the mold proximate the port. The first conductive tab may extend beyond a first lateral edge of the module. The second conductive tab may extend beyond a second lateral edge of the module opposite the first lateral edge of the module. The first and second conductive tabs may extend from the second surface of the module. The second conductive tab may extend around the second lateral edge of the module and be wound on the mold toward the second electrode terminal. The first electrode terminal may extend out of the first surface of the battery toward the first surface of the circuit board. The first conductive tab may extend through a plane of the second surface of the circuit board to couple with the first electrode terminal. The electronic device may extend from the first surface of the circuit board toward the battery. The circuit board may extend substantially parallel to the first surface of the battery to a position near the first electrode terminal. The system may include an adhesive extending across the module. The first end of the adhesive and the second end of the adhesive may be coupled with a battery. The adhesive may include an insulator along a portion of the adhesive, and wherein the insulator extends from the first end of the adhesive across the first electrode terminal. The system may include a flexible coupling extending from the module and including a board-to-board connector at a distal end of the flexible coupling.

Some embodiments of the present technology may encompass a battery system. The system can include a battery characterized by a first surface, a second surface, and a third surface. The second surface and the third surface may be substantially parallel to each other. The first surface of the battery may extend between the second surface and the third surface. The first surface may include a first electrode terminal and a second electrode terminal. The system can include a module coupled to a first surface of the battery and including a circuit board characterized by a first surface and a second surface opposite the first surface. The module may include a mold extending from the first surface of the circuit board toward the battery. The module may include a first conductive tab extending from the second surface of the circuit board to the first electrode terminal. The module may include a second conductive tab extending from the second surface of the circuit board to the second electrode terminal. The module may include a flexible coupling extending from the second surface of the circuit board.

In some embodiments, the mold can extend laterally parallel to the first surface of the cell. The first electrode terminal of the battery may extend from the first surface of the battery. The mold may be held between the first electrode terminal of the battery and the lateral edge of the battery. The second conductive tab may extend around a lateral edge of the module and be wound on the mold toward the second electrode terminal. The second conductive tab may be coupled to the mold by a first adhesive. The second conductive tab may be coupled to the battery by a second adhesive. The second surface of the battery may include a flange extending out of an intersection of the first surface of the battery and the second surface of the battery. The circuit board of the module may extend substantially parallel to the first surface of the battery between the flange and the third surface of the battery. The module may extend across the second electrode terminals of the cells. The circuit board may include test points accessible on a second surface of the circuit board. The flexible coupling may include a connector at a distal end of the flexible coupling. The flexible coupling may be coupled with the second surface of the circuit board at a proximal end of the flexible coupling.

Some embodiments of the present technology may encompass a battery system. The system may include a battery. The battery may include a first electrode terminal, a second electrode terminal, and a port accessible along a first surface of the battery. The system may include a module electrically coupled to the battery. The module may include a mold extending toward the cells. The mold may extend across the second electrode terminal and the port between the first electrode terminal and the lateral edge of the cell. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The module may include a second conductive tab electrically coupling the module with the second electrode terminal. The second conductive tab may extend from a surface of the module opposite the mold. A second conductive tab may extend across the mold around a lateral edge of the module and between the mold and the battery. The system may include a flexible coupling extending from the module from a surface of the module opposite the mold. The system may include an adhesive positioned between the mold and the second conductive tab.

Such techniques may provide a number of advantages over conventional techniques. For example, the present system may provide for compact positioning of battery system components with batteries. Additionally, the battery system components may be positioned to accommodate a defined volume and geometry of the battery. These and other embodiments, as well as many of their advantages and features, are described in more detail in conjunction with the following description and the accompanying drawings.

Drawings

A further understanding of the nature and advantages of the disclosed embodiments may be realized by reference to the remaining portions of the specification and the drawings.

Fig. 1 illustrates a schematic cross-sectional view of a battery cell in accordance with some embodiments of the present technology.

Fig. 2 illustrates a schematic plan view of a battery system, in accordance with some embodiments of the present technique.

Fig. 3 illustrates a schematic front view of a battery system, in accordance with some embodiments of the present technique.

Fig. 4 illustrates a schematic cross-sectional, partial top view of a battery system, in accordance with some embodiments of the present technique.

Fig. 5 illustrates a schematic partial side view of a battery system, in accordance with some embodiments of the present technique.

Fig. 6 illustrates a schematic diagram of a module including a conductive tab in accordance with some embodiments of the present technology.

Several of these drawings are included as schematic illustrations. It should be understood that the drawings are for illustrative purposes only and are not to be construed as scale or ratio unless specifically indicated. In addition, the drawings are provided as schematic diagrams to aid understanding and may not include all aspects or information compared to actual representations and may include enlarged materials for exemplary purposes.

In the drawings, similar components or features may have the same numerical reference. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components and/or features. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label, regardless of the alphabetic suffix.

Detailed Description

Batteries, battery cells and more generally energy storage devices are used in hosts of different systems. In many devices, the battery cells may be designed to take into account a balance of characteristics. For example, including a larger battery may provide increased use between charges, however, a larger battery may require a larger housing, or increased space within the device. As device designs and configurations change, particularly to reduce device size, the available space for additional battery system components may be limited. These constraints may include limitations on available volumes and geometries of such volumes. Conventional devices tend to be limited to larger form factors to accommodate sufficient batteries and associated battery system components. However, the present techniques may overcome these problems by providing a configuration by which battery control system components may be limited in one or more ways to accommodate the volume of the battery or battery system. After showing exemplary cells that may be used in embodiments of the present technology, the present disclosure will describe battery system designs with controlled form factors for use in various devices in which battery cells may be used.

While the remainder of the description will refer to lithium ion batteries, those skilled in the art will readily appreciate that the present techniques are not so limited. The present techniques may be used with any number of batteries or energy storage devices, including other rechargeable battery types and primary battery types as well as secondary batteries or electrochemical capacitors. Furthermore, the present technology may be applied to batteries and energy storage devices used in any number of technologies, which may include, but are not limited to, telephones and mobile devices, watches, glasses, bracelets, foot chains, and other wearable technologies, including fitness devices, handheld electronic devices, laptop computers and other computers, and other devices that may benefit from the use of various of the described battery technologies.

Fig. 1 shows a schematic cross-sectional view of an energy storage device or battery cell 100 in accordance with embodiments of the present technique. The battery cell 100 may be or include a battery cell, and may be one of a plurality of cells coupled together to form a battery structure. As will be readily appreciated, these layers are not shown in any particular scale, and are merely intended to illustrate possible layers of cell material that may be incorporated into one or more cells in an energy storage device. In some embodiments, as shown in fig. 1, the battery cell 100 includes a first current collector 105 and a second current collector 110. In embodiments, one or both current collectors may include a metallic or non-metallic material, such as a polymer or composite, which may include a conductive material. The first current collector 105 and the second current collector 110 may be different materials in embodiments. For example, in some embodiments, the first current collector 105 may be a material selected based on the potential of the anode active material 115, and may be or include copper, stainless steel, or any other suitable metal, as well as non-metallic materials including polymers. The second current collector 110 may be a material selected based on the potential of the cathode active material 120, and may be or include aluminum, stainless steel, or other suitable metals, as well as non-metallic materials including polymers. In other words, the material for the first and second current collectors may be selected based on electrochemical compatibility with the anode active material and the cathode active material used, and may be any material known to be compatible.

In some cases, the metal or nonmetal used for the first and second current collectors may be the same or different. The materials selected for the anode active material and the cathode active material can be any suitable battery material operable in rechargeable battery designs as well as galvanic cell designs. For example, the anode active material 115 may be silicon, graphite, carbon, tin alloys, lithium metal, lithium-containing materials such as Lithium Titanium Oxide (LTO), or other suitable materials that may form an anode in a battery cell. In addition, the cathode active material 120 may be a lithium-containing material, for example. In some embodiments, the lithium-containing material may be a lithium metal oxide such as lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese cobalt oxide, lithium nickel cobalt aluminum oxide, or lithium titanate, while in other embodiments, the lithium-containing material may be lithium iron phosphate or other suitable material that may form a cathode in a battery cell.

The first and second current collectors and the active material may have any suitable thickness. Separator 125 may be disposed between electrodes and may be a polymer film or a material that may allow lithium ions to pass through the structure rather than being otherwise conductive. In a complete cell configuration, the active materials 115 and 120 may additionally include a quantity of electrolyte. The electrolyte may be a liquid comprising one or more salt compounds dissolved in one or more solvents. In embodiments, the salt compound may include a lithium-containing salt compound, and may include one or more lithium salts, including, for example, lithium compounds incorporating one or more halogen elements, such as fluorine or chlorine, as well as other non-metallic elements, such as phosphorus and semi-metallic elements including, for example, boron.

In some embodiments, the salt may include any lithium-containing material that is soluble in an organic solvent. Including with lithium-containing saltsThe solvent may be an organic solvent and may include one or more carbonates. For example, the solvent may include one or more carbonates, including propylene carbonate, ethylene carbonate, ethyl methyl carbonate, dimethyl carbonate, diethyl carbonate, and fluoroethylene carbonate. A combination of solvents may be included, and, for example, propylene carbonate and ethyl methyl carbonate may be included as exemplary combinations. Any other solvent may be included which may enable, for example, dissolution of one or more lithium-containing salts and other electrolyte components, or which may provide useful ionic conductivity, such as greater than or about 5^-10mS/cm。

Although shown as a single layer of electrode material, the battery cell 100 may be any number of layers. While the cell may be constructed of one layer of each of the anode and cathode materials as a sheet, these layers may also be formed in a jelly-roll design or a folded design, a prismatic design, or in any fashion such that any number of layers may be included in the battery cell 100. For embodiments including multiple layers, the tab portions of each anode current collector may be coupled together, which may be the tab portion of each cathode current collector. Once the cells have been formed, a pouch, shell, or case may be formed around the cells to contain electrolyte and other materials within the cell structure, as will be described below. Terminals may extend from the housing to allow electrical coupling for the cells of the device, including an anode terminal and a cathode terminal. The coupling may be directly connected with a load that may utilize electrical power, and in some embodiments, the battery cells may be coupled with a control module that may monitor and control the charging and discharging of the battery cells. Fig. 1 is included as an exemplary battery that may be incorporated into a battery system in accordance with the present technology. However, it should be understood that the present technology may encompass any number of batteries and battery cell designs and materials, which may similarly include charge and discharge capabilities.

Fig. 2 illustrates a schematic plan view of a battery system 200, in accordance with some embodiments of the present technique. As shown, the battery system 200 may include a battery cell or cell 205, which may include any number of battery cells, and a battery module 210. The battery module 210 may be electrically connected with the battery 205 to provide various functions. For example, the battery module 210 may monitor the battery 205 during charge and discharge operations and may ensure that the battery is not overcharged or over-depleted during use. Additionally, the battery module 210 may monitor the overall health of the battery 205 to ensure proper operation. The battery module 210 may be coupled with terminals of the battery, such as one or both of a positive terminal and a negative terminal, in order to provide this function.

The battery module 210 may also include additional electrical connectors, such as couplings, that may allow device components to access battery capacity through the battery module 210. In this manner, the battery module 210 may provide a pass-through function for delivering power from the battery 205. Thus, the battery module 210 may be under a constant load from the battery. The battery 205 may include a cell, which may be similar to the cell 100 described above, and may include a pouch or housing to protect the cell from exposure to the environment. The housing is also operable to retain electrolyte and other materials within the battery cell. To access the battery cells through the housing, one or more terminals or leads may extend through the housing. Some conventional designs may wrap the battery module 210 onto the terminals of the battery 205, which may allow additional material to be provided to protect the terminals and conductive members from fluid contact. However, as device configurations continue to shrink, battery designs change, and manufacturing processes involve more small scale operations with smaller and/or thinner materials, these types of combinations may become less feasible or prone to damage. The present techniques allow battery module 210 to be coupled adjacent to the terminals of battery 205, which may further reduce the overall battery system envelope when incorporated within an electronic device.

Fig. 3 illustrates a schematic cross-sectional view of a battery system 300, in accordance with some embodiments of the present technique. The battery system 300 may include any of the aforementioned components and may include a battery 305 and a module 310. Battery 305 may include a battery cell as previously described in fig. 1, and may include one or more cells included within a pouch or package. For example, in some embodiments, the battery 305 may include a rigid housing, and may include a conductive housing. In an embodiment, the conductive housing may be held at a positive or negative potential and may be held at a negative potential, which may then be operated as a device ground and considered to resemble a neutral connection. Additionally, by using a rigid housing rather than a flexible pouch, manufacturing tolerances in battery size may be reduced, which may provide increased volume for the internal battery cell, which may provide increased capacity over conventional designs. The rigid housing or can may include a flange 306 extending around the battery 305, which may be a cover shell for the remainder of the housing, and may be or include a seamless or substantially seamless form, providing an internal volume that may contain one or more battery cells and electrolyte.

Module 310 may monitor and manage various aspects of the operation of battery 305 and may be a power control module in an embodiment. The module 310 may be electrically coupled with electrode terminals of the battery 305 and may transmit power through a connector 315, which may be any type of connector, such as a board-to-board connector. In some embodiments, the module 310 may be at least partially contained within the lateral dimension of the cell 305 and may be partially retained within the width of the cell 305. Connector 315 may be part of a coupling 320, which may be a flexible coupling extending from module 310. For example, connector 315 may be located at or near a distal end of coupling 320. Coupling 320 may extend partially beyond the lateral dimension of battery 305, as shown, although coupling 320 may be flexible and may be capable of moving within a particular volume when incorporated within a device. However, in some embodiments, module 310 may be partially or completely contained within the lateral width of cell 305. The module 310 may include one or more components including a circuit board 312 and a mold 314, which may include a single mold extending across the circuit board 312, as well as portions in embodiments including discrete portions separately coupled with the circuit board 312, as will be explained further below. The coupling 320 may extend from the circuit board and fold in one or more ways to position the connector 315 under the module 310, or in additional positions, as may be explained further below. Of course, this position may be relative to the orientation of the battery system 300.

For example, in an embodiment, the cell 305 may have a first surface 307, which may be a surface adjacent to the module 310 or facing the module 310. Battery 305 can include a second surface 308 from which flange 306 can extend, and battery 305 can include a third surface 309 opposite second surface 308. The first surface 307 may extend between the second surface 308 and/or the third surface 309 and be partially or substantially perpendicular to the second surface 308 and/or the third surface 309. By "substantially" it is meant that the angle may be less than or greater than perfectly perpendicular, which may account for curved surfaces and machining or manufacturing tolerances. As previously described, the housing of the cell 305 may include a recessed can on which a cover is disposed, and thus, in some embodiments, the first surface 307 and the third surface 309 may be part of a continuous structure and may not have discrete intersection points. Similarly, flange 306 may be formed from a material extending from a first surface and a material defining a second surface, such as where first surface 307 may define a lip at an edge along which a lid as a second surface may be coupled. Regardless, in embodiments, the flange may extend in line with the second surface.

Returning to coupling 320, when folded, connector 315 can be positioned at least partially in line with module 310 along first surface 307 of cell 305, but connector 315 can be positioned at least partially between module 310 and third surface 309 and extend at least partially past third surface 309 between the second and third surfaces in a direction at least partially along or parallel to first surface 307 of the cell. The coupling may be a plurality of flexible couplings, including printed circuit boards, flex boards, or other circuit materials or cables, which may allow for electrical and communication transmission between individual circuit modules or batteries and the system board.

Coupling 320 can be folded in a variety of ways depending on the electronic device configuration to properly position the connector. For example, in one non-limiting embodiment shown, coupling 320 may extend from circuit board 312 toward a lateral edge of battery 305 in a direction substantially parallel to first surface 307. Likewise, by "substantially" it is meant that the components may not be perfectly parallel to one another, but may extend generally in similar directions and are understood in the same manner throughout the present disclosure. Coupling 320 may include a plurality of folds, as will be described in further detail below. The coupling may include one or more arcuate segments that extend the coupling in a plane toward or away from portions of the battery or module, which may take into account geometry and configuration associated with disposing the system within an electronic device. It should be understood that the coupling 320 may take various forms to properly position the connectors for coupling according to the positions of the components to be connected, and fig. 3 shows only one example of the configuration of the coupling 320.

An adhesive may be included to at least partially retain the module 310 against the battery 305, as will be described further below. The adhesive may be one of several adhesives incorporated to hold the module 310 with the cells 305, as will be described in more detail below.

Fig. 4 illustrates a schematic cross-sectional, partial top view of a battery system 400 in accordance with some embodiments of the present technique. As shown in fig. 4, the battery system 400 may include some or all of the components, features, or aspects of the battery cells or systems described above, although some aspects may be adjusted to illustrate additional contemplated embodiments of the present technology. For example, the battery system 400 in this view shows a battery 305 and a module 410. Additional aspects of both battery 305 and module 410 are shown, including multiple locations for electrical and/or mechanical coupling of components. The module 410 may include any of the features of the characteristics of the module 310 described above, but in accordance with some embodiments of the present technique, the module 410 may be positioned with the flexible couplings extending in separate directions, with the module facing the battery. The present techniques may utilize any number of module designs, and in some embodiments may include system-in-package modules that may improve device size over other approaches. For example, a system-in-package module may incorporate multiple integrated circuits on a single carrier substrate or board. This may provide for compact device placement and routing compared to conventional designs. Such a configuration may incorporate components of the module to be bonded to a single side of the module to reduce the module footprint, as will be explained further below.

The battery 305 may include one or more terminals that extend from the battery 305 and provide an electrical path to the battery cell. Additionally, the port 402 may be located along the first surface 307 of the battery 305. Port 402 may be a fill port or other access to battery 305 and may be sealed in some embodiments. The port 402 may be positioned near a lateral edge of the cell 305 or the first surface 307 of the cell 305, such as near or adjacent to a fourth surface 404 of the cell 305, which may intersect or extend into the lateral edge of the first surface 307 of the cell 305.

First and second electrode terminals 405, 407 may extend from first surface 307 of cell 305 or be accessible along first surface 307 of cell 305. In some implementations, each of the first and second electrode terminals can extend to the same location from the first surface 307 of the cell 305. In some embodiments, as shown, the first electrode terminal 405 may extend further outward from the first surface 307 than the second electrode terminal 407. As previously described, in some embodiments, the housing of the cell 305 may be conductive and may be at the potential of one of the electrodes (such as the anode terminal), but the housing may also be held at the cathode potential. The second electrode terminal 407 may represent an electrode terminal that maintains the potential of the case. Thus, the terminal may be a contact, tab or via of the housing. However, the first electrode terminal 405 may be at an opposite potential of the housing and/or the second electrode terminal 407, and may be held or electrically isolated from the rest of the housing. For example, the first electrode terminal 405 may be a cathode terminal, but in other embodiments the terminal may also be held at an anode potential.

To isolate the first electrode terminal 405 from the rest of the housing, a spacer 406 may extend circumferentially through the housing of the cell 305 around the first electrode terminal, including along the first surface 307 of the cell 305. Accordingly, the first electrode terminal 405 may extend farther than the second electrode terminal 407. To limit the extension of the module to accommodate this configuration, in some embodiments, the module 410 may include different conductive tabs of the module and a lateral spatial offset to accommodate the spatial offset of the two terminals.

Module 410 may be electrically coupled with battery 305 at a first electrode terminal and a second electrode terminal. As described above, the module 410 may include the circuit board 312 and the mold 314. The circuit board 312 may be characterized by a first surface 413 and a second surface 414 opposite the first surface. The mold 314 may extend from a first surface 413 of the circuit board 312 toward the battery 305, such as toward the first surface 307 of the battery 305. Similar to the circuit board and the overall module 410, the mold 314 may extend laterally parallel or substantially parallel to the first surface 307 of the cell 305 and may be held with the circuit board 312 between the first electrode terminal 405 and a lateral edge of the cell (such as surface 404). In some embodiments, the module 410 may extend across the port 402 and the second electrode terminal 407. First and second contacts 415, 417 can be included on the second surface 414 to electrically couple the module with the battery 305. Extending between the first contact 415 and the first electrode terminal 405 and electrically coupling the first contact 415 with the first electrode terminal 405 may be a first conductive tab 418. Extending between the second contact 417 and the second electrode terminal 407 and electrically coupling the second contact 417 and the second electrode terminal 407 may be a second conductive tab 420. These connections will be described in further detail below.

In an embodiment, the module 410 may also include a mold 314 that may extend across the circuit board 312. In some implementations, as shown, the mold 314 may extend completely across the circuit board 312 along the first surface 413. For example, the mold 314 may include a first surface 423 and a second surface 424 coupled to the first surface 413 of the circuit board. As described above, the mold 314 may extend from the circuit board 312 toward the battery 305 or toward the first surface 307 of the battery 305. The circuit board 312 may include one or more electronic devices 430 or components extending from either or both of the first surface 413 or the second surface 414 of the circuit board, some of which may be encapsulated by the mold 314. For example, electronic devices 430a and 430b are shown extending from the first surface 413 of the circuit board 312. Device 430 is enclosed by mold 314, which may provide protection for the electronic device. Additional aspects of the components of the circuit board 312, such as accessible aspects for diagnostics, are described further below.

Coupling 320 may also extend or couple with second surface 414 of circuit board 312. Coupling 320 may be electrically coupled to the circuit board in a location between first conductive tab 418 and second conductive tab 420. The coupling may be connected with the second surface of the circuit board at a proximal end of the coupling and may extend in any number of ways to a distal end of the coupling at which the connector 315 may be disposed.

Returning to the conductive tabs that electrically couple the module 410 with the battery 305, a first conductive tab 418 may extend from a first side of the module 410 toward an edge and from the second surface 414 of the circuit board 312. The conductive tab may extend laterally toward the first electrode terminal 405 and may be sealed, welded, or otherwise electrically coupled with the first electrode terminal. As shown, the first electrode terminal 405 may extend outwardly from the first surface 307 of the cell 305 or beyond the first surface 307 of the cell 305 beyond a plane extending along the first surface 423 of the mold 314. The first electrode terminal 405 may also extend to the first surface 413 of the circuit board 312 or toward the first surface 413 of the circuit board 312. The first conductive tab 418 may include a recessed bend or relief as shown, which may extend the first conductive tab from a first plane in line with the second surface of the circuit board to a second plane parallel to the first plane and in line with the external or coupling surface of the first electrode terminal 405.

In some embodiments, the second conductive tab 420 may extend a greater distance than the first conductive tab 418. The second conductive tab 420 may extend from a second lateral edge of the module 410, which may be opposite the first lateral edge from which the first conductive tab 418 may extend. The second conductive tab 420 may also extend from the second surface 414 of the circuit board 312. Once the outer lateral edge of the module 410, such as the proximal surface 404 of the battery 305, is cleared, the second conductive tab 420 may be bent along the module 410 in a direction orthogonal to the first surface 307 of the battery and the first surface 413 of the circuit board 312. Once the first surface 423 of the mold 314 is cleared, the second conductive tab 420 may be bent again along the module 410 in a direction substantially parallel to the first surface 307 of the cell 305 and may extend back from the original direction of extension. For example, from the proximal end of the conductive tab 420 extending from the circuit board, the tab may extend in a first direction to the outer edge of the module 410 and extend back approximately 180 ° along the front surface of the module facing the battery. The second conductive tab 420 may be wound around a lateral edge of the module, as shown toward the second electrode terminal. The distal end of the second conductive tab 420 may then be welded, bonded, or otherwise electrically coupled with the second electrode terminal 407.

As shown, the second conductive tab 420 may extend between the module 410 or the mold 314 and the first surface 307 of the battery. A second conductive tab 420 may extend between the die 314 and the port 402. As described above, various adhesives may be included for component protection and positioning. Although any number of adhesives may be included for decorative and/or coupling purposes, some adhesives may be included in some embodiments of the present technology. A first adhesive 435 may be positioned between the second conductive tab and the first surface 423 of the mold 314. The first adhesive 435 may extend from a first location near the second lateral edge of the module (such as near the port 402) to a second location near the first lateral edge of the module (such as near the second conductive tab 407).

Adhesive 435 along with any of the adhesives described elsewhere may be any number of adhesives, and in some embodiments, may provide environmental protection and/or insulation along with coupling. While in some embodiments, the adhesive is waterproof, in other embodiments, the adhesive may be configured to only protect the components from any environmental contaminants (including dust, lint, or other particles) and to insulate the components from contact. Additionally, the adhesive may be configured to maintain the position of the module 410 relative to the battery 305. The adhesive may be or include a polymeric backing with an applied adhesive. The polymer may be any number of polymers that provide resistivity, structural resiliency, hydrophobicity, or flexibility. For example, in some embodiments, a polyimide backed tape may be used, which may provide a thin film strip that may be flexible to accommodate the topography of the module 310 while limiting the gap or spacing around the module. Although described as an adhesive tape, additional adhesives, sealants, and housings may also be utilized to provide similar protection to the components of the module 410, and are similarly encompassed by the present technology.

For example, the adhesive 435 may include an amount of insulation from the adhesive to protect both the die 314 and the second conductive tab 420. The second adhesive 437 may also be coupled with the second conductive tab 420, such as on a second surface of the second electrode tab opposite the first surface with which the first adhesive 435 may couple the second electrode tab with the mold 314. Second adhesive 437 may couple second conductive tab 420 with first surface 307 of battery 305, which may at least partially secure module 410 to battery 305. In some embodiments, the second adhesive 437 may extend between the port 402 and the second electrode terminal 407. The third adhesive 439 may also secure the module 410 with the battery 305. As shown, the third adhesive 439 may extend across the module 410 and couple with the cells 305 at a first end and a second end of the adhesive.

For example, a first end of third adhesive 439 may be coupled to first surface 307 of cell 305, but the adhesive may also extend around the edges of the cell and wrap around the edges of first surface 307. A third adhesive 439 may extend across the module 410, and a second end of the third adhesive 439 may be coupled with the surface 404 of the battery 305. The third adhesive 439 may also include a quantity of insulation along a portion of the adhesive. For example, the insulator may extend from the first end of the adhesive to a position across the first conductive tab 418 before the insulation stops. The insulator may extend across a portion of the adhesive in contact with the first conductive tab 418 and may extend completely across the first conductive tab 418, which may further protect the tab, which may be at cathode potential.

Turning to fig. 5, a schematic partial side elevation view of a battery system 400 is shown, in accordance with some embodiments of the present technique. As shown in fig. 5, the battery system 400 may include some or all of the components, features, or aspects of the battery system 400 previously described. For example, the battery system 400 in this view shows a battery 305 and a module 410. Additional aspects of both the battery 305 and the module 410 are shown, including additional aspects of some embodiments of the flexible coupling 320.

As previously described, battery 305 may include flange 306 extending outwardly from second surface 308 or extending outwardly from second surface 308 beyond first surface 307. The illustrated view of the module 410 may show the circuit board 312, the die 314, and the second conductive tab 420 extending around the circuit board and the die of the module 410 or wrapped around the circuit board and the die of the module 410. As shown, in some embodiments, the module 410 without the coupling 320 can be held between the second surface 308 and the third surface 309 of the battery 305, and can reside at least partially between the flange 306 and the third surface 309 of the battery 305. Circuit board 312 and mold 314 may each extend substantially parallel to first surface 307 of battery 305, and may be at least partially recessed beyond flange 306 toward first surface 307. For example, the flange 306 may extend from the first surface 307 through the mold 314 and may extend to or beyond the plane of the first surface 413 of the circuit board 312. The flange 306 may extend completely past the circuit board 312, or may in some embodiments extend at least partially past the first surface 413 of the circuit board 312 toward or beyond the second surface 414 of the circuit board 312. By at least partially recessing the module 410 within the volume or envelope of the battery 305, the battery power module may consume less space within the electronic device.

This figure also shows an additional configuration of a coupling 320 that may extend from the second surface 414 of the circuit board 312 in a direction toward the third surface 309 of the battery 305. While the present techniques contemplate any number of coupling geometries as previously described, in some embodiments, the flexible coupling 320 may be bent or extended back across the module 410 as shown, and may extend to the battery 305 or toward the battery 305. In some embodiments, coupling 320 may extend through the plane of first surface 307 and extend across and may contact third surface 309 of battery 305. The coupling may be bent back over the first surface 307 and may include one or more additional bends, and then to the distal end of the coupling 320 where the connector 315 may be coupled.

Fig. 6 illustrates a schematic diagram of a module 600 including a conductive tab in accordance with some embodiments of the present technology. It should be understood that any number of conductive materials or tab geometries may be used in the present technique, and thus the example of the module 600 is not intended to limit the present technique. The module 600 may include some or any of the components of the modules 310 or 410 described above, and may include a circuit board 312. The circuit board 312 may include a first contact 602 and a second contact 604 that may be electrically coupled to electrode terminals on the battery, as previously described. The first conductive tab 418 may be coupled to and extend from the first contact 602, and the second conductive tab 420 may be coupled to and extend from the second contact 604.

The conductive tabs may include various geometries to provide surfaces for coupling with electrode tabs of a battery. Although the conductive tabs 418 and 420 may be rectangular, in some embodiments, the conductive tabs may be characterized by any number of geometric shapes that may be shaped to accommodate nearly any shape of contact or terminal. The first and second ends of each conductive tab may be or form a weld tab that may provide a landing space and surface to which the electrode tab may be welded, bonded, or otherwise adhered to an associated contact or terminal. The conductive tab may further include an extension between the first end and the second end of the conductive tab.

The extension portion may include one or more notches, regions, thicknesses, or widths along the length of the extension portion. The extension portion may be shaped or configured to facilitate bending, folding or manipulation of the conductive tab to improve the contact surface location of the solder tab, as well as to limit shear or other forces on the conductive tab. In addition, in embodiments, the end portions of the conductive tabs may have different shapes or sizes. For example, although the contacts may be of similar size, in some embodiments, the battery terminals may be larger or smaller than the circuit board contacts. Thus, the first end of the conductive tab may be sized to receive a contact of a circuit board, while the second end of the conductive tab may be sized to receive an electrode terminal of a battery. Thus, the present technology may provide any number of variations to accommodate both the module and the battery.

The module 600 may include a coupling 320 that may couple with the circuit board 312 along a surface similar to the conductive tabs described previously. Coupling 320 may be electrically coupled to pad 605 using surface mount technology, which may allow for electrical coupling to a circuit board. Additional temperature sensitive adhesive 610 may be included to further couple and support coupling 320. A temperature sensitive adhesive may be included to ensure that coupling is maintained during coupling with the module, which may include relatively high temperature processes that may reduce coupling or damage other adhesives, such as pressure sensitive adhesives.

A second surface of circuit board 312, on which conductive tabs and couplings 320 may sit, may be exposed facing away from the battery to which module 600 is engaged, as previously described. Such exposure may allow access to test points 615 or pads that may provide diagnostic testing of the power module, system, or battery. Thus, in some embodiments, no additional molding or covering may be included on the second surface of the circuit board. As previously mentioned, the test point may be accessible through or around the external adhesive, or removal of the adhesive may provide access to the test point.

Battery systems according to embodiments of the present technology may provide limited footprint expansion for control modules associated with the battery. Because many electronic devices have limited volume for batteries, the present techniques allow more of this volume to be used for battery cell materials, which may increase or maintain battery capacity in smaller devices. In addition, while many battery configurations are characterized by non-uniform external topography, modules according to some embodiments of the present technology may maintain a substantially uniform outer surface by providing an internal mold and component configuration that accommodates non-uniform battery characteristics.

In the previous description, for purposes of explanation, numerous specific details were set forth in order to provide an understanding of embodiments of the present technology. It will be apparent, however, to one skilled in the art that certain embodiments may be practiced without some or with additional details of these specific details.

Several embodiments are disclosed, and those skilled in the art will recognize that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the embodiments. In addition, many well known processes and elements have not been described in detail in order to avoid unnecessarily obscuring the present technology. Accordingly, the above description should not be taken as limiting the scope of the present technology.

If a range of values is provided, it is understood that each intervening value, to the smallest part of the unit of the lower limit, between the upper and lower limit of that range, is also specifically disclosed unless the context clearly dictates otherwise. Any stated value in the range, or any narrower range between any stated or intervening value in a stated range, is encompassed. The upper and lower limits of these smaller ranges may independently be included in the range or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the technology range, subject to any specific exclusion within that range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included. If multiple values are provided in the list, any ranges encompassing or based on any of these values are similarly specifically disclosed.

As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a material" includes a plurality of such materials, and reference to "an element" includes reference to one or more elements known to those skilled in the art, equivalents thereof, and so forth.

Furthermore, the words "comprise," "comprising," and "contain," when used in this specification and the following claims, are intended to specify the presence of stated features, integers, components, or operations, but they do not preclude the presence or addition of one or more other features, integers, components, operations, acts, or groups thereof.