Abstract:
This invention includes an improved interconnect assembly for use in rechargeable battery packs for laptop computers. The invention eliminates manufacturing defects resulting from the hand soldering processes of the prior art. The assembly provides interconnection for rechargeable cells oriented end to end, in parallel rows. Insulated runners provide interconnection to a bus located along the center of the end to end cells. The bus is a flexible circuit that couples to a printed circuit board. In one preferred embodiment, the bus is less than two inches in diameter and less than the diameters of the parallel rows of end to end cells in length. The assembly eliminates the need for hand soldering, eliminates cumbersome wire routing, and offers multiple insulation features that prevent electrical shorts.

Description:
BACKGROUND 
     1. Technical Field 
     This invention relates generally to rechargeable batteries for laptop computers, and more specifically to a system for interconnecting cells and circuits within such a rechargeable battery pack. 
     2. Background Art 
     Notebook style, or “laptop”, computers are becoming more and more popular. Prices for these small, portable computers now rival those of their larger, bulkier desktop model predecessors. Students and business people enjoy the ability to work on their computers while on the go. Manufacturers have even responded to the demand for laptop computers by introducing new products like “tablet” style computers that allow users to write on the screen with a special pen, thereby emulating a tablet of paper. 
     Laptop computers derive their portability from rechargeable batteries. The rechargeable batteries, from the outside, sometimes resemble interchangeable computer components like CD-ROM or floppy disk drives. One such example is shown in U.S. Design Pat. No. D440201. These designs make the batteries easy to insert into standard bays within the laptop computer. 
     The inside of these batteries, however, is quite complex. The batteries typically include from six to ten individual cells, coupled in parallel and series combinations. Additionally, these batteries generally include sophisticated circuitry, including battery protection circuits, microprocessor circuits, fuel gauging circuits and charging circuits. These circuits are typically mounted on a rigid printed circuit board. The board may include some form of standard connector that couples to the laptop computer. 
     A problem exists in that it is difficult to connect the cells, which are often packaged in cylindrical steel cans, to the printed circuit board. By far the most popular way to connect the cells to the board is by hand soldering a flexible wire from a metal tab welded to the can, to the printed circuit board. The problem with this hand soldering method is reliability. If the soldering technician is not diligent, cold solder joints may result, thereby compromising reliability of the battery pack. Additionally, solder balls and bridges may short elements within the battery pack, again compromising reliability. 
     There is thus a need for an improved interconnect system within computer battery packs. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a prior art internal battery cell configuration for laptop computer battery packs. 
     FIG. 2 illustrates the runner in accordance with the invention. 
     FIG. 3 illustrates the bus in accordance with the invention. 
     FIG. 4 illustrates an exploded view of a cell arrangement with the components of the interconnect structure in accordance with the invention. 
     FIG. 5 illustrates a rechargeable battery assembly with an interconnect structure in accordance with the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A preferred embodiment of the invention is now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise: the meaning of “a,”“an,” and “the” includes plural reference, the meaning of “in” includes “in” and “on.” 
     Referring now to FIG. 1, illustrated therein is a typical internal battery cell configuration for laptop computer battery packs. A configuration of this type is typical for battery packs used in computers manufactured by the major computer manufacturers. The invention described herein could be utilized on a variety of different cell types and configurations, but as the configuration of FIG. 1 is one of the most popular being used in laptop computers today, it will be used for exemplary purposes. 
     The configuration is made of a plurality of rechargeable cells 101-108. These cells 101-108 are generally lithium ion cells, as lithium-based batteries offer extremely high energy densities. The exemplary cells 101-108 shown in FIG. 1 are referred to by the industry as “18-650” cells. The “ 18 ” cornes from the 18 mm diameter, and the “650” refers to their 65 mm length. The cells  101 - 108  have positive and negative terminals, with the positive terminal typically indicated with a crimped ring about the cell. For example, ring  109  indicates the positive end of cell  103 . The cells are typically configured in a series-parallel configuration. For example, cells  101  and  102  may be coupled in parallel, coupled serially with the parallel combination of cells  103  and  104 , coupled serially with the parallel combination of cells  105  and  106 , coupled serially with the parallel combination of cells  107  and  108 . The geometric packaging effect is that the cells  101 - 108  are physically coupled in parallel rows of two cells, e.g. one parallel row is cells  101  and  108 , being disposed end to end, coupled in geometric parallel with cells  102 , 107 , cells  103 , 106 , and so on. 
     Flexible metal tabs are welded to the ends of the cells. For example the positive ends  112 ,  113  of cells  101 , 102  may be coupled with a flexible metal tab, while the negative ends  114 , 115  of cells  101 , 102  are coupled to the positive ends  109 , 116  of cells  103 , 104 , by way of flexible metal tab  110 . Paper insulators  117 , 118  are optionally included to ensure that the flexible metal tab  110  does not contact the non-terminal portion of the cell. 
     End cells, e.g.  104 ,  105 , may be coupled by way of a metal tab, as is the case in this exemplary embodiment. Lead cells, e.g.  101 , 108 , are preferably mechanically coupled by way of a durable adhesive, like Kapton® tape  119 . 
     Prior art solutions would then hand solder wire from a flexible metal tab (like tab  110 ) to a printed circuit board. As stated above, a myriad of manufacturing and field defects can occur as a result of hand soldering processes. Additionally, hand soldering is slow and labor intensive. Factories seeking to maintain six-sigma quality control are unable to do so with hand soldering processes. This invention provides an inexpensive, efficient interconnect system suitable for welding machines. The invention reduces both cost and manufacturing defects. 
     Referring now to FIG. 2, illustrated therein is one component of the interconnect system. This component will be herein referred to as a “runner”, as it forms an electrical connection that “runs” from the flexible metal tabs to the bus. The runner includes a plastic casing  202  that encompasses a metal tab  201 . The plastic casing  202  is generally triangular in cross section, with two of the sides  203 , 204  having concave curvatures to mate between pairs of cylindrical cells. By way of example, if 18-650 cells are used, the concave curvatures of sides  203 , 204  would have 9 mm radii, neglecting tolerances, to accommodate the outer curves of the cell. The plastic housing may be made from any of a number of plastics, including styrene, polystyrene, ABS, polycarbonates and the like. A preferred plastic is Noryl GTX 830. 
     The flexible metal tab  201  is similar to those used to couple cells together (as in FIG.  1 ). The flexible metal tab  201  is exposed through two apertures  205 , 206  in the plastic casing  202 . The apertures  205 - 206  allow machine welding as will be described below. The flexible tab preferably includes a perpendicular member  207  for coupling to the tabs in a battery pack. 
     There are several manufacturing options available for construction of the runner. A preferred method includes insert molding. In this method, the flexible metal tab  201  is inserted into the cavity of a mold, whereupon molten plastic is injected about the tab  201 . Tooling holes  208 , 209  facilitate plastic flow about the tab  201 . Other alternatives include tooling the plastic housing  202  by way of injection molding, and then manually inserting the flexible metal tab  201  into the casing  202 . Optional barbs (not shown) in the tab  201  may mate with holes  208 , 209  to keep the tab  201  in place. 
     Referring now to FIG. 3, illustrated therein is the bus portion  300  of the invention. The bus  300  is a flexible circuit, preferably constructed of Kapton encapsulated metal conductive traces, e.g.  301 . Such flexible circuits are known in the art, as is described in U.S. Pat. No. 6,153,834. The traces  301  extend beyond the Kapton  302 , thereby forming metal tabs  303  that may be welded to. The bus  300  optionally includes folds  304  to accommodate the particular battery cell structure. The bus  300  of this circuit has a width  305  of no more than two inches, due to the overall structure of the invention. The length  306  of the bus is less than the sum of the diameters of cells across which it spans. Terminals  307  are provided that facilitate coupling to a printed circuit board. 
     Referring now to FIG. 4, illustrated therein is an exploded view of a cell arrangement  101 - 108  with the components of the interconnect structure in accordance with the invention. The ultimate goal of the invention is to connect the cells  101 - 108  to a printed circuit board  400 . The printed circuit board includes conductive traces and associated circuitry, which may include battery protection circuits, microprocessor circuits, fuel gauging circuits and charging circuits. The conductive traces facilitate, among other things, delivery of power from the cells  101 - 108  to a connecter  401  that ultimately delivers the power to the host device. 
     As illustrated, the terminals  307  of the bus  300  are electrically coupled to the printed circuit board  400 . The preferred method of coupling is by way of a hot bar welding process, although soldering is an alternative, for example in a reflow process. The bus  300  is oriented such that the tabs  303  align with the metal tabs  201  of the runners. The runners are aligned such that the perpendicular members, e.g.  207 , align with each of the metal tabs  110  on the cell terminals. 
     Referring now to FIG. 5, illustrated therein is a rechargeable battery assembly with an interconnect structure in accordance with the invention. The bus tabs  303  have been welded to the runner metal tabs  201  through the apertures  205  in the plastic casing  202 . The perpendicular tabs  207  have each been welded to the battery tabs  110 . The welding process is preferably carried out by way of spot welding, although pinch welding and soldering will also work. 
     The plastic casings  202  have been seated between adjoining cells  102 , 103 . Note that in addition to facilitating a welding process, thereby improving efficiency, the plastic casings  102  also provide an extra insulating function. The insulating function prevents tabs from shorting to either tabs or other cell housings. Note also that the bus  300  is generally the most expensive component of the circuit, as Kapton is very robust, patented product of the DuPont company and tends to be rather expensive. The structure shown in FIG. 5 greatly reduces cost over prior art solutions in that the bus is kept less than two inches in width. The length is less than the diameter of the parallel cells (i.e. the length of the bus  300  is less than the combined widths of cells  101 , 102 , 103 , 104 ). Note also that the bus  300  covers the “fold” in the cells, as a folded tab  500  couples cells  104  and  105 . The bus  300  is thus positioned down the center of the parallel combinations of end to end cells in the cell configuration. 
     While FIG. 5 is an exemplary embodiment, it represents an embodiment that will accommodate many laptop batteries. The structure includes eight 18-650 cells, in serial combinations of pairs of parallel cells. Five runners  202 , 501 - 504  are used, each coupled to a tab on the bus  300 . The bus  300  runs across the interior  506  of the cells  101 - 108 , thereby coupling to a center portion  505  of the printed circuit board  400 . The net result is a low-cost, high reliability interconnect system that may be implemented in mass production facilities. 
     While the preferred embodiments of the invention have been illustrated and described, it is clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions, and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the following claims. For example, while the exemplary embodiment utilized eight 18-650 cells in a series parallel combination, it will be clear that numerous other combinations of cell numbers and configurations may also employ the invention.