Battery pack including an indicator circuit

The invention is directed toward a battery pack. The battery pack includes at least one electrochemical cell; a case; a plate; an indicator circuit; and a battery-to-internal volume ratio. The case includes at least one open end. The plate is placed over the at least one open end. The plate includes a terminal plate, a base plate, or any combination thereof. The indicator circuit includes an integrated circuit and an antenna. The indicator circuit is affixed to the plate. The battery-to-internal volume ratio is greater than about 0.52.

FIELD OF THE INVENTION

The invention relates to a battery pack including an indicator circuit.

BACKGROUND OF THE INVENTION

Wireless communications, including radio frequency identification (RFID) and other near field communication (NFC) protocols, are gaining in popularity for applications such as security, inventory management, access control, and the like. The number of smart phones that include RFID or NFC protocols is growing along with the various applications of passive or active transponders, such as RFID circuits and NFC circuits. Such communications circuits may be coupled with an antenna that modulates, and in some instances emits, a wireless communication signal that can be read by a reader, such as a smartphone.

Electrochemical cells, or batteries, are commonly used as electrical energy sources. An electrochemical cell contains a negative electrode, typically called the anode, and a positive electrode, typically called the cathode. The anode contains an active material that can be oxidized. The cathode contains an active material that can be reduced. The anode active material is capable of reducing the cathode active material. A separator is disposed between the anode and cathode. An electrolyte is also included within the electrochemical cell. The aforementioned components are generally disposed in a can. A battery pack may include at least one electrochemical cell within a case. The battery pack may have specified external dimensions that, in part, limit the internal volume of the case available for the at least one electrochemical cell and other battery pack components.

Battery testers may be used to determine characteristics of a battery, or a battery pack, such as the remaining battery capacity. An exemplary type of a common battery tester that is placed on a battery is known as a thermochromic-type tester. In a thermochromic battery tester, a circuit may be completed by a consumer manually depressing one or two button switches. Once the circuit is completed, the consumer has electrically connected the battery to the thermochromic tester. The thermochromic tester may include a silver resistor, e.g., a flat silver layer that has a variable width so that the electrical resistance also varies along its length. As current travels through the silver resistor, the dissipated power generates heat that changes the color of a thermochromic ink display that is placed over the silver resistor. The thermochromic ink display may be arranged as a gauge to indicate the relative capacity of the battery. However, it is typically necessary for the consumer to inconveniently hold the battery and/or remove the battery from the device in order to test the battery using the battery tester.

Accordingly, there exists a need for a battery pack including an indicator circuit that does not require manual interaction between the consumer and the battery pack. In addition, the battery pack including an indicator circuit may also include advanced processing and communication capabilities. There also exists a need for a battery pack including an indicator circuit that does not detrimentally reduce the internal volume of the case that is available for the at least one electrochemical cell and other battery pack components.

SUMMARY OF THE INVENTION

The invention is directed toward a battery pack. The battery pack includes at least one electrochemical cell; a case; a plate; an indicator circuit; and a battery-to-internal volume ratio. The case includes at least one open end. The plate is placed over the at least one open end. The plate includes a terminal plate, a base plate, or any combination thereof. The indicator circuit includes an integrated circuit and an antenna. The indicator circuit is affixed to the plate. The battery-to-internal volume ratio is greater than about 0.52.

In another embodiment, the invention is directed toward a battery pack. The battery pack includes at least one electrochemical cell; a case; a plate; an indicator circuit; and a battery-to-internal volume ratio. The case includes an open end, a closed end, and a sidewall therebetween. The plate is placed over the one open end. The plate is a terminal plate. The indicator circuit includes an integrated circuit and an antenna. The indicator circuit is affixed to the closed end of the case. The battery-to-internal volume ratio is greater than about 0.52.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed towards a battery pack including an indicator circuit. The battery pack includes at least one electrochemical cell, or battery, within a case. The indicator circuit is capable of sending and/or receiving a wireless communication signal. The indicator circuit includes an integrated circuit (IC) and an antenna. The indicator circuit may be electrically coupled to the at least one electrochemical cell. The indicator circuit may wirelessly communicate characteristics of the at least one electrochemical cell, such as voltage or capacity, to a reader, such as a smartphone.

The electrochemical cell is a device that is capable of converting chemical energy within the active materials of the electrochemical cell by means of an electrochemical reduction-oxidation (redox) reaction. David Linden,Handbook of Batteries, 1.3 (4thed. 2011). The electrochemical cell consists of an anode, a cathode, and an electrolyte. Id. One or more electrochemical cells may be referred to as a battery. Electrochemical cells, or batteries, may be primary or secondary. Primary batteries are meant to be discharged, e.g., to exhaustion, only once and then discarded. Primary batteries are described, for example, in David Linden,Handbook of Batteries(4thed. 2011). Secondary batteries are intended to be recharged. Secondary batteries may be discharged and recharged many times, e.g., more than fifty times, a hundred times, or more. Secondary batteries are described, for example, in David Linden,Handbook of Batteries(4thed. 2011). Accordingly, batteries may include various electrochemical couples and electrolyte combinations. It should be appreciated that the invention applies to both primary and secondary batteries of aqueous, nonaqueous, ionic liquid, and solid state systems that are included within the battery pack. Battery packs including primary and secondary batteries of the aforementioned systems are thus within the scope of this application and the invention is not limited to any particular embodiment.

Battery packs are available in varying sizes and dimensions. The International Electrotechnical Commission (IEC) and the American National Standards Institute (ANSI), for example, have established standard sizes and dimensions for batteries and battery packs available to consumers at retail. The IEC has set standard sizes and dimensions, for example, for battery packs, such as what is commonly referred to as a 9V alkaline battery pack. A 9V battery pack, for example, has a prismatic, or rectangular, shape with a maximum height of about 48.5 mm; a maximum length of about 26.5 mm; and a maximum width of about 17.5 mm. In addition, individual battery or device manufacturers may designate the dimensions for battery packs that may not be generally available at retail, such as lithium ion prismatic batteries. Prismatic batteries of this type may have a height of less than about 5 mm; a length of less than about 42 mm; and a width of less than about 34 mm. It should be appreciated that the present invention applies to battery packs of various sizes and dimensions set by the IEC or ANSI, such as an ANSI 1604 battery pack; an ANSI 7.2H5 battery pack; an ANSI 7.2K5 battery pack; an ANSI 8.4H5 battery pack; and an ANSI 8.4K5 battery, as well as battery pack sizes and dimensions that are designated by individual battery or device manufacturers.

The case may have any suitable shape, for example, a prismatic shape, an oval shape, a polygonal shape with rounded edges, or any other suitable shape. The case may have a prismatic shape, for example, a shape comprising at least two parallel plates, such as a shape that is rectangular or square. The case may be of any conventional type commonly used for battery packs. The case may be made of any suitable material. The material may be, for example, a flexible metal, such as aluminum, aluminum alloy, stainless steel, nickel-plated steel (pre or post-plated), or the like. The material may also be, for example, a non-conductive and non-magnetic material, such as plastic, polymer, or the like. The case should have sufficient dimensions and internal volume to include the at least one electrochemical cell and the indicator circuit.

The case may be formed via a stamping process, such as deep-drawing. The case may be formed via a molding process, such as injection molding. The case may be formed into, for example, two halves that may be brought together to form a complete case, such a case may be referred to as a clam-shell case. The case may include at least one open end. The case may have a closed end that is integrally formed within the case when the case is formed by, for example, either deep drawing or injection molding. The closed end may be opposite the open end of the case. The case may include a first open end and a second open end. The case may include a sidewall that runs from the open end to the closed end of the case. The case may include a sidewall that runs from the first open end of the case to the second open end of the case. The sidewall may have a height H. A plate may be placed over the at least one open end. The plate may be a terminal plate or a base plate.

The terminal plate may be placed over the at least one open end of the case to close the battery pack. In some embodiments, such as when the battery pack includes the clam-shell case, the terminal plate may be placed over the first open end of the case. The terminal plate may be made from any suitable material. The material may be, for example, a flexible metal, such as aluminum, aluminum alloy, stainless steel, nickel-plated steel (pre or post-plated), or the like. The material may also be, for example, a non-conductive and non-magnetic material, such as plastic, polymer, or the like. The terminal plate may be formed by any suitable process, such as stamping or injection molding. The terminal plate may include a positive battery pack terminal and a negative battery pack terminal. The positive battery pack terminal and the negative battery pack terminal may be made from any suitable material that is conductive. The material may be metal, such as nickel, nickel-plated steel, stainless steel, brass, or the like. The positive battery pack terminal and the negative battery pack terminal may be optionally plated with nickel, gold, brass, or another suitable material presenting a low electrical-contact resistance between the positive battery pack terminal and the negative battery pack terminal and, for example, the electrical contacts within a device to which the positive battery pack terminal and the negative battery pack terminal are in electrical connection with the device.

A portion of the sidewall of the case may extend past the terminal plate when the terminal plate is seated within the at least one open end of the case. The portion of the sidewall of the case extending past the seated terminal plate can be crimped over the terminal plate to seal the case of the battery pack closed. Alternatively, the terminal plate may be placed within, for example, the two halves of a clam-shell case. The two halves of the clam-shell case may be welded, for example ultrasonically welded, to close the battery pack.

In some embodiments, such as when the battery pack includes the clam-shell case, the base plate may be used. The base plate may be placed over the second open end of the case to close the second open end of the case to form the battery pack. The base plate may be made from any suitable material. The material may be, for example, a flexible metal, such as aluminum, aluminum alloy, stainless steel, nickel-plated steel (pre or post-plated), or the like. The material may also be, for example, from a non-conductive and non-magnetic material, such as plastic, polymer, or the like. The base plate may be formed by any suitable process, such as stamping or injection molding.

The base plate may be placed over the second open end of the case. A portion of the sidewall of the case may extend past the base plate when the base plate is seated within the second open end of the case. The portion of the sidewall of the case extending past the seated base plate can be crimped over the base plate to seal the case of the battery pack closed. Alternatively, the base plate may be placed within, for example, the two halves of the clam-shell case. The two halves of the clam-shell case may be welded, for example ultrasonically welded, to close the battery pack.

The indicator circuit may include the integrated circuit (IC) and the antenna. The IC may include a circuit of transistors, resistors, diodes, inductors, and/or capacitors constructed on a single substrate, such as a semiconductor wafer or chip, or a metal, polymer, or ceramic substrate, in which the discreet components are interconnected to perform a given function. The IC may comprise a communications circuit and/or an analog-to-digital converter (ADC) electrically coupled together to perform a function, or any number of functions. The IC may be electrically connected to a system ground in order for the IC to perform its function(s). The IC may include circuits that include, but not be limited to, an indication circuit; a power circuit; a communications circuit, such as an RFID circuit or block or a NFC circuit or block; an input/output circuit or port; and the like. The IC may physically co-locate, for example, the communications circuit and ADC side-by-side or physically integrate them together. The IC may also comprise an application specific integrated circuit (ASIC) that is specifically manufactured to encompass the performance of the function, or any number of functions, that are required. The function may be, for example, to determine a specified condition of the at least one electrochemical cell within the battery pack or the battery pack and relay that information to the reader in the form of function information. The function may also be, for example, to signally communicate a notification of the specific condition of the at least one electrochemical cell within the battery pack or the battery pack. The function may be, for example, to provide an indication of the specified condition of the at least one electrochemical cell within the battery pack or the battery pack which may include audible, visible, or pallesthesia indications. Pallesthesia is the ability to sense a vibration and a pallesthesia indication is a mechanical or electromechanical means to provide the sense of vibration.

The IC may be of any suitable shape. The IC may have a rectangular or square shape with a length, a width, and a height. The IC may be active, semi-active, battery-assisted passive, or may be passive. The length of the IC may be less than about 3 mm, for example between about 1.0 mm to about 2.0 mm. The width of the IC may be less than about 3 mm, for example between about 0.5 mm and about 2 mm. The height of the IC may be less than about 1.0 mm, for example between about 0.02 mm and about 0.10 mm.

The communications circuit may be any suitable communications circuitry such as radio-frequency identification (RFID) circuitry and near field communication (NFC) circuitry as included within, for example, ISO/IEC 14443 (proximity cards), 15693 (vicinity cards), 15961, 15962, 15963, and 18000 communication standards; Bluetooth circuitry as included within, for example, IEEE 802.15.1 communication standard; Bluetooth Low Energy, or Bluetooth Smart, circuitry as included within, for example, IEEE 802.15.6 communications standard; Wi-Fi circuitry as included within, for example, IEEE 802.11 communication standard; Zigbee circuitry as included within, for example, IEEE 802 communication standard; and any suitable fixed wireless communication circuitry. The communications circuit may utilize any suitable frequency bands such as low-frequency (from about 125 kHz to about 134.2 kHz and from about 140 kHz to about 148.5 kHz); high frequency (HF) (13.56 MHz); ultra-high frequency (UHF) (860-956 MHz); or microwave frequency (2.4-5.8 GHz). In addition, other communications circuitry may be used, such as audible or inaudible sound or visible light.

The antenna may include at least one antenna trace that may define a single antenna or multiple antennas. The antenna may be a single ended antenna, a dipole antenna, a loop antenna, or any other suitable type of antenna. The loop antenna, for example, may include one or more turns or windings of the at least one antenna trace. The at least one antenna trace may include a first antenna terminal and a second antenna terminal. The first antenna terminal and the second antenna terminal may provide joint connections for solder, conductive adhesive, ultrasonic welding, thermosonic bonding, thermo-compression bonding, or crimping, for example, to the integrated circuit (IC). The first antenna terminal and the second antenna terminal may be electrically coupled to the IC.

The antenna may include any number of loops required to achieve the desired read range of the communications circuit. The corresponding IC input capacitance and antenna inductance must be accounted for in deciding how many loops and/or how many turns per loop may be used to provide a LC (inductance and capacitance) tank circuit with a tunability range to meet the communications circuit and reader resonance frequencies.

The at least one antenna trace, the first antenna terminal, and the second antenna terminal may be made from copper, aluminum, silver, gold, or other conductive metals. Other examples include conductive polymers, conductive glues, and conductive carbon, such as graphite. The at least one antenna trace, the first antenna terminal, and the second antenna terminal may be printed or painted. The at least one antenna trace of the antenna may be printed by a machine that defines the antenna through the use of screen, gravure, or ink jet printing to apply the material onto a subject surface. The printing may be completed via RF sputtering techniques; impact or pressure techniques that define material on the subject surface; metal foil mask techniques; and etch techniques, or heat or light activation techniques that activate the material that is applied to the subject surface.

The at least one antenna trace, the first antenna terminal, and the second antenna terminal may be made from foil. The at least one antenna trace, the first antenna terminal, and the second antenna terminal may be a pre-formed wire that is either insulated or bare. If the pre-formed wire is bare, it may be covered by a non-conductive sheet, a non-conductive tape, a non-conductive flexible substrate, or a non-conductive shrink wrap.

The at least one electrochemical cell may have a positive terminal and a negative terminal. The IC may be electrically coupled, in series, parallel, or a combination thereof, to the positive terminal and the negative terminal of the battery. For example, a conducting trace, such as a lead, may connect the negative terminal of the battery to the IC. Similarly, a conducting trace, such as a lead, may connect the positive terminal of the battery to the IC. The conducting trace can be formed from any suitable material that is electrically conductive, such as conductive polymers; conductive glues; conductive carbon, such as graphite; and conductive metals, such as aluminum, nickel, silver, copper, gold, and tin. The conducting trace may be printed directly on the battery; may be a thin metal wire affixed to the battery; may be a thin insulated wire attached to the battery; or any other suitable form that provides electrical connection from the positive terminal of the battery to the IC and from the negative terminal of the battery to the IC. The conducting trace may be electrically isolated from the metal can of the battery. For example, the conducting trace may extend from the IC to the negative terminal of the battery and remain electrically isolated from the battery till it is electrically coupled to the negative terminal of the battery. Similarly, the conducting trace may extend from the IC to the positive terminal of the battery and remain electrically isolated from the battery till it is electrically coupled to the positive terminal of the battery. The conducting trace may be coupled to the positive terminal and the negative terminal of the battery, for example, by a conductive adhesive, such as a silver epoxy, by ultrasonic welding, by resistance welding, by laser welding, or by mechanical pressure.

The IC of the indicator circuit may perform any number of functions with respect to the at least one electrochemical cell within the battery pack. The IC may provide function information regarding: power output of the at least one electrochemical cell or the battery pack; rate of discharge of the at least one electrochemical cell or the battery pack; when the at least one electrochemical cell or the battery pack is nearing the end of its useful life; and state of charge of the at least one electrochemical cell or the battery pack. The IC may also provide: over-discharge protection; over-charge protection; remaining capacity determination; voltage determination; cycle life determination; and power management. Power management functions may include battery pack identification; battery pack state of health; battery pack protection; cell balancing; fuel gauging; charge control; voltage conversion; load regulation; powering the battery pack on/off; power setting adjustment; allow or prevent recharging; battery pack by-pass; temperature monitoring; and charging rate adjustment. The IC may be used, for example, in a battery pack including an indicator circuit to provide information about the battery pack to, for example, the consumer through the use of the reader, such as a smartphone. The IC may also be configured with a unique identifier, such as an RFID circuit equivalent, that indicates either a unique sequence of numbers/symbols or information such as, for example, manufacturing date, lot number, serial number, and the other identifiable information of the battery pack.

The battery pack including an indicator circuit may also include a magnetic diverter if, for example, the can of the at least one electrochemical cell within the battery pack, or if the case of the battery pack, is metal. The magnetic diverter may be any material with high magnetic permeability at a specified frequency and with low electrical conductivity. The magnetic diverter may be, for example, a thin, flexible, ferrite material, such as iron or iron alloys with a body centered cubic crystal structure. Other materials may be used as the magnetic diverter which provide a high magnetic permeability such as, for example, nickel, or cobalt and their corresponding alloys. Other materials for the magnetic diverter also include oxides which are not substantially electrically conductive. The magnetic diverter may be, for example, about 30 micrometers to about 300 micrometers thick.

The magnetic diverter may shield the antenna of the indicator circuit from metal components within the battery pack, such as the case and the metal can of the at least one electrochemical cell. The magnetic diverter may be, for example, placed between the antenna and the at least one electrochemical cell. The magnetic diverter may be a film affixed, for example, to the surface of the antenna and/or the integrated circuit. The magnetic diverter may be painted or coated on the surface of the antenna and/or the integrated circuit. The magnetic diverter may be a film affixed to the internal surface of the case. The magnetic diverter may be painted or coated on the internal surface of the case.

The IC may be affixed to, or integral within, the terminal plate, the base plate, or the case. The IC may be affixed to, or integral within, a printed circuit board (PCB). The IC can be affixed to the terminal plate, the base plate, the case, or the PCB by an adhesive or a weld. Suitable adhesives include glues, epoxies, and any other suitable adhesive that is, for example, thermally conductive and electrically insulating. Suitable welding methods include pressure bonding, ultrasonic welding, and combinations thereof or any other acceptable welding processes. The IC may be encapsulated in a protective material, such as an epoxy, prior to or after being affixed to the terminal plate, the base plate, the case, or the PCB.

The PCB may be affixed to, or integral within, the terminal plate, the base plate, or the case. The PCB, on or within which a wiring pattern or circuit may be formed, may include a plurality of safety devices, power terminals, external connection terminals, and the like that provide functional features, such as communication, antenna(e), and thermal heat sinks. The PCB may comprise one or more layers, each having its own wiring pattern and such a PCB may be referred to as a multi-layer PCB. The wiring pattern may comprise conductive traces or conductive foil traces. A multi-layer PCB may comprise vias between layers to provide electrical connection between their wiring patterns. Examples of safety devices may include a protective module, a positive-temperature-coefficient (PTC) thermistor, and the like. The protective module may include, for example, a switching device, a control-circuit unit, a resistor, a capacitor, a fuse, and the like. Examples of power terminals and external-connection terminals may include PCB contact pads.

The PCB may be electrically coupled with the at least one electrochemical cell. The PCB may be electrically coupled to the at least one electrochemical cell in series, parallel, or any combination thereof. For example, conducting traces or a flexible circuit can connect the negative terminal of the at least one electrochemical cell to the PCB and the positive terminal of the at least one electrochemical cell to the PCB. The conducting traces can be formed from any suitable material that is electrically conductive, such as conductive polymers, conductive glues, conductive carbon, such as graphite, and conductive metals, such as aluminum, nickel, silver, copper, gold, and tin. The conducting traces may be printed directly on the at least one electrochemical cell; may be a thin metal wire affixed to the at least one electrochemical cell; may be a thin insulated wire attached to the at least one electrochemical cell; or any other suitable form that provides electrical connection from one terminal of the at least one electrochemical cell to the PCB and the other terminal of the at least one electrochemical cell to the PCB.

The battery pack may also include an insulator. The insulator may be placed, for example, between the indicator circuit and the at least one electrochemical cell. The insulator may be made from a suitable material and in any suitable shape to prevent, for example, the at least one electrochemical cell from contacting the indicator circuit. The insulator may be made of any suitable, insulative material, such as plastic, paper, ceramic, fiber board, composites thereof, and any combinations thereof.

The at least one electrochemical cell within the battery pack may have a volume. The at least one electrochemical cell within the battery pack may occupy a total volume. The battery pack may have an internal volume. The internal volume of the battery pack may be defined as the space that is bounded by, for example, the terminal plate that is placed over the open end of the case; the sidewall of the case; and the closed end of the case. The internal volume of the battery pack may alternatively be defined as the space that is bounded by, for example, the terminal plate that is placed over the first open end of the case; the base plate that is placed over the second open end of the case; and the sidewall of the case. A ratio of the total volume that is occupied by the at least one electrochemical cell to the internal volume of the battery pack may be referred to as the battery-to-internal volume ratio of the battery pack. The volume occupied by the at least one electrochemical cell; the total volume occupied by the at least one electrochemical cell; the internal volume of the battery pack; and the battery-to-internal volume ratio will be fixed by the design of the battery pack and may be calculated by a battery pack designer using, for example, a computer-aided design (CAD) program.

The total volume of the at least one electrochemical cell within the battery pack may be at least about 11.2 cm3. The total volume of the at least one electrochemical cell within the battery pack may be, for example, from about 11.2 cm3to about 21.0 cm3. The internal volume of the battery pack may be less than about 21.5 cm3. The internal volume of the battery pack may be, for example, from about 11.4 cm3to about 21.0 cm3. The battery-to-internal volume ratio may be greater than about 0.52. The battery-to-internal volume ratio may be, for example, from about 0.52 to about 0.98.

An ANSI 1604 9V primary alkaline battery pack, for example, may include a battery pack that has an internal volume of about 17.8 cm3. The 9V primary battery pack may also include six cylindrical primary electrochemical cells. Each individual cylindrical primary electrochemical cell may have a volume of about 1.9 cm3. The total volume of the six cylindrical primary electrochemical cells may be about 11.4 cm3(6 electrochemical cells·1.9 cm3/electrochemical cell). The battery-to-internal volume ratio of the ANSI 1604 9V primary alkaline battery pack may be about 0.64 (11.4 cm3/17.8 cm3).

An ANSI 1604 9V primary alkaline battery pack, for example, may include a battery pack that has an internal volume of about 17.5 cm3. The ANSI 1604 9V primary battery may include six prismatic primary electrochemical cells. Each individual prismatic primary electrochemical cell may have a volume of about 2.6 cm3. The total volume of the six prismatic primary electrochemical cells may be about 15.6 cm3(6 electrochemical cells·2.6 cm3/electrochemical cell). The battery-to-internal volume ratio of the 9V primary alkaline battery pack may be about 0.89 (15.6 cm3/17.5 cm3).

The reader may be any device capable of reading the indicator circuit. Specific examples of the reader include a smartphone, tablet, personal computer (PC) with NFC adapter, dedicated RFID indicator circuit reader, a dedicated NFC indicator circuit reader, a handheld computing device, or a wand antenna electrically coupled to a computing device. The reader may be used to excite the IC by transmitting an interrogation signal or may transmit a “wake-up” signal to the IC. The interrogation signal may be, for example, a RF pulse of a predetermined frequency used to energize the circuit in the IC and provide power to the IC to transmit its function information. The “wake-up” signal may, for example, be a RF pulse, but the IC may use power from another source to power the IC and to transmit its function information. The IC may periodically send a signal or may send a signal based upon the change of the function information that may be read by the reader. The reader may include a display to visibly present the function information or an audible device capable of audibly presenting the function information. The reader may also include algorithms to interpret and/or modify the function information before presenting.

Referring toFIG. 1, an exemplary battery pack110is shown. The battery pack110includes a case112; a terminal plate114; a positive battery pack terminal116; a negative battery pack terminal118; an insulator120; an indicator circuit126; and at least one electrochemical cell128. The indicator circuit126includes an antenna122; an integrated circuit (IC)124; and a communications circuit160. The case112includes a closed end140, an open end142, and a sidewall144therebetween. The sidewall144has a height H. The terminal plate114is placed over the open end142of the case112. The indicator circuit126is affixed to the terminal plate114of the case112. The indicator circuit126is in electrical communication with the at least one electrochemical cell128. The at least one electrochemical cell128is in electrical communication with the positive battery pack terminal116and the negative battery pack terminal118.

Referring toFIG. 2, an exemplary battery pack210is shown. The battery pack210includes a case212; a terminal plate214; a positive battery pack terminal216; a negative battery pack terminal218; an insulator220; an indicator circuit226; and at least one electrochemical cell228. The indicator circuit226includes an antenna222; an integrated circuit (IC)224; and a communications circuit260. The case212includes a closed end240, an open end242, and a sidewall244therebetween. The sidewall244has a height H. The terminal plate214is placed over the open end242of the case212. The indicator circuit226is affixed to the closed end240of the case212. The indicator circuit226is in electrical communication with the at least one electrochemical cell228. The at least one electrochemical cell228is in electrical communication with the positive battery pack terminal216and the negative battery pack terminal218.

Referring toFIG. 3, an exemplary battery pack310is shown. The battery pack310includes a case312; a terminal plate314; a base plate330; a positive battery pack terminal316; a negative battery pack terminal318; an insulator320; an indicator circuit326; and at least one electrochemical cell328. The indicator circuit326includes an antenna322; an integrated circuit (IC)324; and a communications circuit360. The case312includes a first open end346, a second open end348, and a sidewall344therebetween. The sidewall344has a height H. The terminal plate314is placed over the first open end346of the case312. The base plate330is placed over the second open end348of the case312. The indicator circuit326is affixed to the terminal plate314. The indicator circuit326is in electrical communication with the at least one electrochemical cell328. The at least one electrochemical cell328is in electrical communication with the positive battery pack terminal316and the negative battery pack terminal318.

Referring toFIG. 4, an exemplary battery pack410is shown. The battery pack410includes a case412; a terminal plate414; a base plate430; a positive battery pack terminal416; a negative battery pack terminal418; an insulator420; an indicator circuit426; and at least one electrochemical cell428. The indicator circuit426includes an antenna422; an integrated circuit (IC)424; and a communications circuit460. The case412includes a first open end446, a second open end448, and a sidewall444therebetween. The sidewall444has a height H. The terminal plate414is placed over the first open end446of the case412. The base plate430is placed over the second open end448of the case412. The indicator circuit426is affixed to the base plate430. The indicator circuit426is in electrical communication with the at least one electrochemical cell428. The at least one electrochemical cell428is in electrical communication with the positive battery pack terminal416and the negative battery pack terminal418.

Referring toFIG. 5, an exemplary battery pack510is shown. The battery pack510includes a case512; a terminal plate514; a positive battery pack terminal516; a negative battery pack terminal518; an insulator520; a magnetic diverter550; an indicator circuit526; and at least one electrochemical cell528. The indicator circuit526includes an antenna522and an integrated circuit (IC)524. The case512includes a closed end540, an open end542, and a sidewall544therebetween. The sidewall544has a height H. The terminal plate514is placed over the open end542of the case512. The integrated circuit524is affixed to the terminal plate514. The antenna522is integral to the case512. The magnetic diverter550is affixed to the sidewall of the case512between the at least one electrochemical cell528and the antenna522. The indicator circuit526is in electrical communication with the at least one electrochemical cell528. The at least one electrochemical cell528is in electrical communication with the positive battery pack terminal516and the negative battery pack terminal518.

Referring toFIG. 6, an exemplary battery pack610is shown. The battery pack610includes a case612; a terminal plate614; a positive battery pack terminal616; a negative battery pack terminal618; an insulator620; a base plate630; a magnetic diverter650; an indicator circuit626; and at least one electrochemical cell628. The indicator circuit626includes an antenna622and an integrated circuit (IC)624. The case612includes a first open end646, a second open end648, and a sidewall644therebetween. The sidewall644has a height H. The terminal plate614is placed over the first open end646of the case612. The base plate630is placed over the second open end648of the case612. The integrated circuit624is affixed to the base plate630. The antenna622is integral to the case612. The magnetic diverter650is affixed to the sidewall644of the case612between the at least one electrochemical cell628and the antenna622. The indicator circuit626is in electrical communication with the at least one electrochemical cell628. The at least one electrochemical cell628is in electrical communication with the positive battery pack terminal616and the negative battery pack terminal618.

Referring toFIG. 7, an exemplary terminal plate714is shown. The terminal plate714includes a positive battery pack terminal716; a negative battery pack terminal718; and an indicator circuit726. The indicator circuit726includes an antenna722; an integrated circuit (IC)724; and a communications circuit760. The indicator circuit726is in electrical communication with the positive battery pack terminal716and the negative battery pack terminal718. The positive battery pack terminal716and the negative battery pack terminal718may be placed in electrical connection with at least one electrochemical cell when the terminal plate714is used within a battery pack.

Referring toFIG. 8, an exemplary base plate830is shown. The base plate830includes an indicator circuit826. The indicator circuit826includes an antenna822; an integrated circuit (IC)824; and a communications circuit860. The indicator circuit826may be placed in electrical communication with a positive battery pack terminal and a negative battery pack terminal when the base plate830is used within a battery pack.

Referring toFIG. 9, an exemplary volume that may be occupied by at least one electrochemical cell within a battery pack910is shown. The battery pack910includes a case912and at least one electrochemical cell928. The at least one electrochemical cell928occupies a volume within the case912and the volume is represented by the dotted area. The total volume that is occupied by the at least one electrochemical cell928may be referred to as the total battery volume. The cross-section of the battery pack910inFIG. 9shows, for example, three electrochemical cells of a total of six electrochemical cells that are within battery pack910. In addition, the at least one electrochemical cell928withinFIG. 9is shown as a cylindrical cell. It should be appreciated that the representation withinFIG. 9is exemplary and in no way limits the invention in number, shape, or size of the at least one electrochemical cell within the battery pack912.

Referring toFIG. 10, an exemplary internal volume within the battery pack910ofFIG. 9is shown. The battery pack910includes a case912and a terminal plate914. The case912includes a closed end940, an open end942, and a sidewall944therebetween. The sidewall944has a height H. The terminal plate914is placed over the open end942of the case912. The internal volume of the battery pack is defined as the space that is bounded by the terminal plate914that is placed over the open end942of the case912; the sidewall944of the case912; and the closed end940of the case912. The internal volume is represented by the dotted area. In addition, the battery pack910withinFIG. 10is shown as a prismatic, and more specifically a rectangular, battery pack. It should be appreciated that the representation withinFIG. 10is exemplary and in no way limits the invention in shape or size of the battery pack910.

Referring toFIGS. 9 and 10, the battery pack910will have a battery-to-internal volume ratio that is equal to the total volume occupied by the at least one electrochemical cell928divided by the internal volume of the battery pack910.

Referring toFIG. 11, an exemplary volume that may be occupied by at least one electrochemical cell within a battery pack1110is shown. The battery pack1110includes a case1112and at least one electrochemical cell1128. The at least one electrochemical cell1128occupies a volume within the battery pack1110. The volume is represented by the dotted area. The total volume that is occupied by the at least one electrochemical cell1128may be referred to as the total battery volume. The cross-section of the battery pack1110shows, for example, three electrochemical cells of a total of six electrochemical cells that are within battery pack1110. In addition, the at least one electrochemical cell1128is shown as a cylindrical cell. It should be appreciated that the representation withinFIG. 11is exemplary and in no way limits the invention in number, shape, or size of the at least one electrochemical cell within the battery pack1110.

Referring toFIG. 12, an exemplary internal volume within the battery pack1110ofFIG. 11is shown. The battery pack1110includes a case1112, a terminal plate1114, and a base plate1130. The case1112includes a first open end1146, a second open end1148, and a sidewall1144therebetween. The sidewall1144has a height H. The terminal plate1114is placed over the first open end1146of the case1112. The base plate1130is placed over the second open end1148of the case1112. The internal volume of the battery pack is defined as the space that is bounded by the terminal plate1114that is placed over the first open end1146of the case1112; the base plate1130that is placed over the second open end1148of the case1112; and the sidewall1144of the case1112. The internal volume is represented by the dotted area. In addition, the battery pack1110withinFIG. 12is shown as a prismatic, and more specifically a rectangular, battery pack. It should be appreciated that the representation withinFIG. 12is exemplary and in no way limits the invention in shape or size of the battery pack1110.

Referring toFIGS. 11 and 12, the battery pack1110will have a battery-to-internal volume ratio that is equal to the total volume occupied by the at least one electrochemical cell1128divided by the internal volume of the battery pack1110.