FILM-BASED BATTERY HOLDER

A battery pack is provided. The battery pack includes a first battery that includes a first terminal and second terminal on the opposite side of the battery from the first terminal. The battery pack further includes a battery holder. The battery holder includes a flexible substrate and a first conductive element disposed on the flexible substrate. The first conductive element has a first contact region to electrically engage with the first terminal. The battery holder further includes a second conductive element that has a second contact region to electrically engage with the second terminal when the flexible substrate is folded over the first battery.

DETAILED DESCRIPTION OF THE INVENTION

The present invention advantageously provides an apparatus, system and method for a battery holder and battery pack. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

One embodiment of the present invention advantageously provides a battery holder system and method. Referring now to the drawing figures, in which like reference designators refer to like elements, there is shown inFIG. 1a system constructed in accordance with the principles of the present invention and designated generally as “10.” System10includes battery12, substrate14, first conductive element16and second conductive element18. Battery12may be a coin or button cell battery, among other battery types. Battery12includes first terminal20and second terminal22in which one of first terminal18and second terminal22is a positive terminal of battery12and the other one of first terminal20and second terminal22is a negative terminal of battery12.

Substrate14is a flexible substrate that is constructed of a non-conductive film such as KAPTON or polyethylene terephthalate (PET) film, among other flexible non-conductive films. Substrate14includes primary side24and secondary side26opposite primary side24. Substrate14further includes first portion28and second portion30in which one of first portion28and second portion30is arranged to fold over the other portion of substrate14, as discussed in detail with respect toFIG. 3.

First conductive element16is a conductive trace disposed on first portion28and primary side24of substrate14. First conductive element16includes first conductive region32on which battery12may be disposed. First conductive region32is arranged to electrically engage battery12, i.e., first terminal20or second terminal22of battery12. First contact region32is formed by a portion of first conductive element16in which the portion of first conductive element16is disposed on substrate14in a pattern and/or or non-pattern layout.

Second conductive element18is a conductive trace disposed on first portion28, second portion30and primary side24of substrate14in which second conductive element18is electrically isolated from first conductive element16. Second conductive element18includes second contact region34arranged to electrically engage battery12, i.e., electrically engage the other battery terminal not electrically engaged to first contact region32, when second portion30of substrate14is folded over first portion28of substrate14. Alternatively, first portion28may be folded over second portion30. Second contact region34is formed by a portion of second conductive element18disposed on substrate14in a pattern or non-pattern layout. First conductive element16and second conductive element18further include respective device contact points36aand36b(collectively referred to as “device contact point36”) that provide an area or point where an electronic device, such as an EAS tag, may electrically engage system10. The device contact point36may be metal grommet (FIGS. 6-8).

First conductive element16and/or second conductive element18may be formed by conductive ink in which adhesive35is disposed adjacent to or in between the conductive ink pattern to secure or retain battery12to substrate14, i.e., helps keep first conductive region32and second conductive region34electrically engaged to battery12. In another embodiment, conductive epoxy may be used in which the conductive epoxy secures battery12to substrate14while electrically engaging battery12. Alternatively, first conductive element16and/or second conductive element18may be formed from other conductive materials that electrically engage terminals20and22, adhere to substrate14and flex such that substrate14may be folded around a portion of battery12.

FIGS. 2-3illustrate system10at different stages of assembly. In particular, battery12is positioned on first contact region32(FIG. 2) such that first terminal of battery12electrically engages first contact region32. Second portion30of substrate14is folded over at least a portion of battery12and first portion32such that second contact region34electrically engages battery12, i.e., electrically engages second terminal22(FIG. 3). Referring toFIG. 4, electronic article surveillance (EAS) tag37is illustrated. In particular, EAS tag37is an active tag that uses power supplied by system10, i.e., battery pack, to communicate with an EAS interrogation system and/or actuate an audible alarm. Non-contact portions of traces can be coated with insulating substance(s), e.g., non-conductive epoxy, to help prevent short circuits.

FIG. 5illustrates an alternative embodiment of system10that is arranged to electrically engage two batteries12and38. System10includes battery12and battery38in which battery38includes third terminal40and fourth terminal42. Substrate14includes first portion28having first contact region32and second portion30having second contact region34, as described above with respect toFIGS. 1-3. Substrate14further includes third conductive element44having third contact region46disposed on third portion48and primary side24of substrate14. In particular, third contact region46is formed by a portion of third conductive element44disposed on substrate14in a pattern and/or non-pattern layout. Further, third conductive element44may be connected to device contact point36via second conductive element18or may be connected directly to device contact point36. Third contact region is arranged to electrically engage one of third terminal40and fourth terminal42when battery38is disposed on third contact region46.

Substrate14further includes forth conductive element50(FIG. 7) disposed on secondary side26of substrate14. Fourth conductive element50includes fourth contact region52(FIG. 7) disposed on second portion30and secondary side26of substrate14. Fourth contact region52is formed by a portion of fourth conductive element50disposed on substrate14in a pattern and/or non-pattern layout. Fourth conductive element50is electrically connected to first conductive element16via device contract point36, i.e., metal grommet. Adhesive35is disposed adjacent to or in between first, second, third and fourth conductive elements16,18,44and50, i.e., next to conductive ink traces, such that batteries12and38are secured to substrate14in order to help keep batteries12and38electrically engaged with respective contact regions. Alternatively, the conductive elements may be formed using conductive epoxy, thereby eliminating the need for adhesive35. The embodiment ofFIG. 5is not limited to two batteries in which additional conductive elements may be added to a longer substrate such that more batteries may be accommodated. Moreover, first, second, third, fourth and/or additional conductive elements may be arranged to form a different electrical circuit than illustrated inFIG. 5depending on whether batteries12and38need to be in an electrical series and/or parallel connection to each other.

FIGS. 5-8illustrate different stages during production of this embodiment of system10. Batteries12and38are disposed on first contact region32and third contact region46, respectively. First contact region32electrically engages first terminal20while third contact region46electrically engages third terminal40. Second portion30is folded over at least a portion of battery12and/or first portion28, as discussed above with respect toFIGS. 2-3. First and second portions28and30of substrate14are then folded around at least a portion of second battery38and/or third portion48such that fourth contact region52is electrically engaged to fourth terminal42of second battery38.

The invention provides a battery holder and battery pack that can be mass produced and cut to the appropriate size. The battery holder also allows for different size coin cell batteries to be used with the same battery holder as the placement of contact regions on substrate14does not require an exact coin size battery, thereby allowing various types of coin batteries to be accommodated. Since the battery holder is not made of sheet metal, the battery holder, i.e., substrate14, is less susceptible to corrosion, limits static discharge, weighs less and requires less space. Furthermore, when system10is assembled, as illustrated inFIGS. 3 and 8, exposure of conductive elements (16,18,44and50) and contact regions are substantially reduced or eliminated such that electrical components that come into contact with the film are not electrically charged by batteries12and38.

FIG. 9is a flowchart of an exemplary process for assembling a battery pack having a flexible substrate including at least a first conductive element16including first contact region32and second conductive element18including a second contact region34. A first battery is positioned on a first contact region of battery holder, i.e., substrate14(Block S100). For example, battery12is positioned on first contact region32or second contact region34. A portion of the battery holder, i.e., flexible substrate14, is folded over at least a portion of the first battery (Block S102). For example, second portion30may be folded over at least a portion of battery12and first portion28, as illustrated inFIGS. 3 and 6, such that second contact region34electrically engages battery12. A second battery is positioned on a third contact region of battery holder, i.e., substrate14(Block S104). In one embodiment, battery38is positioned on third contact region48such that third contact region46electrically engages battery38, as illustrated inFIGS. 6-7. First and second portions of the battery holder, i.e., flexible substrate14, are folded over the first battery (Block S106). For example, as illustrated inFIG. 7, first portion28and second portion30are folded over battery38and third portion48such that fourth contact region52electrically engages battery38. Alternatively, Blocks S104and S106may be skipped based on design need such as if the battery holder ofFIGS. 1-3is being assembled. Also, Blocks S102and S104may be swapped such that the second battery is positioned on the flexible substrate before the second portion of the battery holder is folded over the first battery.

System10may also be arranged to hold cylindrical shaped batteries, among other battery types known in the art. System10provides an easy to replace battery that lowers cost because system10can directly contact the PCB of a device without an expensive on-board metal or combination plastic/metal battery holder. The time and cost associated with soldering the battery holder to the PCB is also eliminated. Further, system10does not require biasing elements, e.g., springs, to hold the battery in place against battery holder contact terminals to ensure proper contact since conductive epoxy and/or adhesive is used, thereby reducing manufacturing cost and complexity. Also, system10may be removably insertable within the electronic device (FIG. 4), thereby providing an easily replaceable battery pack. For example, substrate14and battery12, i.e., battery holder and battery, may be provided as a single unit, e.g., to a retailer, such that a consumer can purchase the battery pack at the retailer to replace an existing battery within the consumer's electronic device. Retailers can also easily use the battery pack for replacement of dead batteries in active EAS tags.