PATENT DOCUMENT

Publication Number: US-11552339-B2
Application Number: US-202016880076-A
Country: US
Kind Code: B2

Title: Battery pack with overmolded module

Abstract:
Battery systems according to embodiments of the present technology may include a battery including a first electrode terminal and a second electrode terminal accessible along a first surface of the battery. The battery systems may also include a module electrically coupled with the battery. The module may include a first mold extending toward the battery. The first mold may define a recess along a first surface of the first mold proximate the first electrode terminal and the second electrode terminal. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The first electrode terminal may be at least partially positioned within a space defined by the recess defined by the first mold. The module may also include a second conductive tab electrically coupling the module with the second electrode terminal.

Claims:
What is claimed is: 
     
       1. A battery system comprising:
 a battery, wherein the battery includes a first electrode terminal and a second electrode terminal accessible along a first battery surface of the battery; 
 a module electrically coupled with the battery, the module comprising:
 a first mold extending toward the battery, wherein the first mold comprises a first mold surface and a second mold surface opposite the first mold surface, and wherein the first mold defines a recess along the first mold surface proximate the first electrode terminal and the second electrode terminal, 
 a first conductive tab electrically coupling the module with the first electrode terminal, wherein the first electrode terminal is at least partially positioned within a space defined by the recess defined by the first mold, and 
 a second conductive tab electrically coupling the module with the second electrode terminal; and 
 
 a circuit board comprising a first circuit board surface and a second circuit board surface opposite the first circuit board surface, wherein the second mold surface is coupled with the first circuit board surface, and wherein the module further comprises a second mold coupled with the second circuit board surface. 
 
     
     
       2. The battery system of  claim 1 , wherein the battery further comprises a port positioned proximate a lateral edge of the first battery surface of the battery, wherein the first mold defines a recessed ledge in the first mold surface of the first mold extending towards a lateral edge of the first mold proximate the port. 
     
     
       3. The battery system of  claim 2 , further comprising a first adhesive positioned between the port and the first mold, wherein the first adhesive extends across the recessed ledge. 
     
     
       4. The battery system of  claim 1 , wherein the second conductive tab at least partially defines a volume between a first end of the second conductive tab coupled with the module and a second end of the second conductive tab coupled with the second electrode terminal. 
     
     
       5. The battery system of  claim 4 , further comprising a spacer including a second adhesive seated in the volume between the first end of the second conductive tab and the second end of the second conductive tab. 
     
     
       6. The battery system of  claim 1 , wherein an electronic device extends from the second circuit board surface of the circuit board opposite the first circuit board surface of the circuit board, and wherein the second mold encapsulates the electronic device. 
     
     
       7. The battery system of  claim 6 , wherein the circuit board extends substantially parallel to the first battery surface of the battery to a location substantially in line with a flange of a second battery surface of the battery normal to the first battery surface of the battery. 
     
     
       8. The battery system of  claim 7 , wherein the second mold extends along the circuit board to an edge of the circuit board proximate the flange, and wherein the first mold extends along the circuit board to a position offset from the edge of the circuit board in a direction parallel to the first battery surface of the battery. 
     
     
       9. The battery system of  claim 1 , further comprising a flexible coupling extending from the module and comprising a board-to-board connector at a distal end of the flexible coupling. 
     
     
       10. 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 one another, 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 first mold extending from the first surface of the circuit board toward the battery, 
 a second mold extending from the second surface of the circuit board, 
 a first conductive tab extending from the module to the first electrode terminal, and 
 a second conductive tab extending from the module to the second electrode terminal; and 
 
 a flexible coupling extending from the circuit board parallel to the first surface of the battery in a direction towards the second surface of the battery. 
 
     
     
       11. The battery system of  claim 10 , wherein the first mold defines a recess along a first surface of the first mold proximate the first electrode terminal, wherein the first surface of the first mold is opposite a second surface of the first mold coupled with the first surface of the circuit board, wherein the first electrode terminal of the battery extends from the first surface of the battery, and wherein the first electrode terminal is at least partially positioned within the recess defined by the first mold. 
     
     
       12. The battery system of  claim 10 , wherein the second conductive tab at least partially defines a volume between a first end of the second conductive tab coupled with the module and a second end of the second conductive tab coupled with the second electrode terminal, and wherein the battery system further comprises a spacer including an adhesive seated in the volume between the first end of the second conductive tab and the second end of the second conductive tab. 
     
     
       13. The battery system of  claim 10 , wherein the second surface of the battery comprises a flange extending proud 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 to a location substantially in line with the flange. 
     
     
       14. The battery system of  claim 13 , wherein the second mold extends along the second surface of the circuit board to an edge of the circuit board proximate the flange, wherein the first mold extends along the circuit board to a position offset from the edge of the circuit board in a direction parallel to the first surface of the battery, and wherein the first mold extends towards the first surface of the battery beyond a plane parallel to the first surface of the battery and defined by an external edge of the flange. 
     
     
       15. The battery system of  claim 10 , wherein the second mold defines a chamfer along an outer edge of the second mold at a location along the second mold proximate the first electrode terminal of the battery. 
     
     
       16. The battery system of  claim 10 , wherein the battery defines an arcuate indentation along an intersection of the first surface of the battery and the third surface of the battery. 
     
     
       17. The battery system of  claim 10 , wherein the flexible coupling comprises a connector at a distal end of the flexible coupling, and wherein the flexible coupling is folded about the second mold to position the connector at least partially between the module and the third surface of the battery in a direction along the first surface of the battery. 
     
     
       18. The battery system of  claim 10 , wherein the battery further comprises a port positioned proximate a lateral edge of the first surface of the battery, wherein the first mold defines a recessed ledge in a first surface of the first mold extending towards a lateral edge of the first mold proximate the port, and wherein the module further comprises a first adhesive positioned between the port and the first mold, and wherein the first adhesive extends across the recessed ledge of the first mold. 
     
     
       19. A battery system comprising:
 a battery, wherein the battery includes a first electrode terminal, a second electrode terminal, and a port accessible along a first surface of the battery; 
 a module electrically coupled with the battery, the module comprising:
 a mold extending toward the battery, wherein the mold defines a recessed ledge in a first surface of the mold extending towards a lateral edge of the mold proximate the port, 
 a first conductive tab electrically coupling the module with the first electrode terminal, and 
 a second conductive tab electrically coupling the module with the second electrode terminal, wherein the second conductive tab at least partially defines a volume between a first end of the second conductive tab coupled with the module and a second end of the second conductive tab coupled with the second electrode terminal; 
 
 a flexible coupling extending from the module parallel to the first surface of the battery; 
 a first adhesive positioned between the port and the mold, wherein the first adhesive extends across the recessed ledge of the mold; and 
 a spacer including a second adhesive seated in the volume between the first end of the second conductive tab and the second end of the second conductive tab.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     The present application claims the benefit of priority to U.S. Provisional Application No. 62/854,518, filed May 30, 2019, the contents of which are hereby incorporated by reference in their entirety for all purposes. 
    
    
     TECHNICAL FIELD 
     The present technology relates to battery systems. More specifically, the present technology relates to battery component configurations incorporating a module with a battery. 
     BACKGROUND 
     Batteries are used in many devices. As devices in which batteries are housed reduce in size, the available space for battery cells and associated system materials may limit placement options. 
     SUMMARY 
     Battery systems according to embodiments of the present technology may include a battery including a first electrode terminal and a second electrode terminal accessible along a first surface of the battery. The battery systems may also include a module electrically coupled with the battery. The module may include a first mold extending toward the battery. The first mold may define a recess along a first surface of the first mold proximate the first electrode terminal and the second electrode terminal. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The first electrode terminal may be at least partially positioned within a space defined by the recess defined by the first mold. The module may also include a second conductive tab electrically coupling the module with the second electrode terminal. 
     In some embodiments, the battery further may include a port positioned proximate a lateral edge of the first surface of the battery. The first mold may define a recessed ledge in the first surface of the first mold extending towards a lateral edge of the first mold proximate the port. The systems may also include a first adhesive positioned between the port and the first mold. The first adhesive may extend across the recessed ledge. The second conductive tab may at least partially define a volume between a first end of the second conductive tab coupled with the module and a second end of the second conductive tab coupled with the second electrode terminal. The systems may also include a spacer including a second adhesive seated in the volume between the first end of the second conductive tab and the second end of the second conductive tab. 
     The systems may also include a circuit board having a first surface with which the first mold is coupled along a second surface of the first mold opposite the first surface of the first mold. An electronic device may extend from a second surface of the circuit board opposite the first surface of the circuit board. The module may also include a second mold coupled with the second surface of the circuit board. The second mold may encapsulate the electronic device. The circuit board may extend substantially parallel to the first surface of the battery to a location substantially in line with a flange of a second surface of the battery normal to the first surface of the battery. The second mold may extend along the circuit board to an edge of the circuit board proximate the flange. The first mold may extend along the circuit board to a position offset from the edge of the circuit board in a direction parallel to the first surface of the battery. The systems may also 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 also encompass battery systems including 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 one another. 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 systems may include a module coupled with the 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 first mold extending from the first surface of the circuit board toward the battery. The module may include a second mold extending from the second surface of the circuit board. The module may include a first conductive tab extending from the module to the first electrode terminal. The module may include a second conductive tab extending from the module to the second electrode terminal. The module may also include a flexible coupling extending from the circuit board parallel to the first surface of the battery in a direction towards the second surface of the battery. 
     In some embodiments, the first mold may define a recess along a first surface of the first mold proximate the first electrode terminal. The first surface of the first mold may be opposite a second surface of the first mold coupled with the first surface of the circuit board. The first electrode terminal of the battery may extend from the first surface of the battery. The first electrode terminal may at least partially be positioned within the recess defined by the first mold. The second conductive tab may at least partially define a volume between a first end of the second conductive tab coupled with the module and a second end of the second conductive tab coupled with the second electrode terminal. The battery system may also include a spacer including an adhesive seated in the volume between the first end of the second conductive tab and the second end of the second conductive tab. The second surface of the battery may include a flange extending proud 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 to a location substantially in line with the flange. 
     The second mold may extend along the second surface of the circuit board to an edge of the circuit board proximate the flange. The first mold may extend along the circuit board to a position offset from the edge of the circuit board in a direction parallel to the first surface of the battery. The first mold may extend towards the first surface of the battery beyond a plane parallel to the first surface of the battery and defined by an external edge of the flange. The second mold may define a chamfer along an outer edge of the second mold at a location along the second mold proximate the first electrode terminal of the battery. The battery may define an arcuate indentation along an intersection of the first surface of the battery and the third surface of the battery. The flexible coupling may include a connector at a distal end of the flexible coupling. The flexible coupling may be folded about the second mold to position the connector at least partially between the module and the third surface of the battery in a direction along the first surface of the battery. The battery may also include a port positioned proximate a lateral edge of the first surface of the battery. The first mold may define a recessed ledge in a first surface of the first mold extending towards a lateral edge of the first mold proximate the port. The module may also include a first adhesive positioned between the port and the first mold. The first adhesive may extend across the recessed ledge of the first mold. 
     Some embodiments of the present technology may also encompass battery systems including 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 systems may include a module electrically coupled with the battery. The module may include a mold extending toward the battery. The mold may define a recessed ledge in a first surface of the mold extending towards a lateral edge of the mold proximate the port. 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 at least partially define a volume between a first end of the second conductive tab coupled with the module and a second end of the second conductive tab coupled with the second electrode terminal. The module may include a flexible coupling extending from the module parallel to the first surface of the battery. The system may include a first adhesive positioned between the port and the mold. The first adhesive may extend across the recessed ledge of the mold. The system may also include a spacer including a second adhesive seated in the volume between the first end of the second conductive tab and the second end of the second conductive tab. 
     Such technology may provide numerous benefits over conventional technology. For example, the present systems may provide a compact positioning of battery system components with a battery. Additionally, the battery system components may be positioned to accommodate a defined volume and geometry of a battery. These and other embodiments, along with many of their advantages and features, are described in more detail in conjunction with the below description and attached figures. 
    
    
     
       BRIEF DESCRIPTION OF THE 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    shows a schematic cross-sectional view of a battery cell according to some embodiments of the present technology. 
         FIG.  2    shows a schematic plan view of a battery system according to some embodiments of the present technology. 
         FIG.  3    shows a schematic elevation view of a battery system according to some embodiments of the present technology. 
         FIG.  4    shows a schematic, cross-sectional, partial top view of a battery system according to some embodiments of the present technology. 
         FIG.  5    shows a schematic partial side elevation view of a battery system according to some embodiments of the present technology. 
         FIG.  6    shows a schematic partial cross-sectional elevation view along line A-A of  FIG.  3    of a battery system according to some embodiments of the present technology. 
         FIG.  7    shows a schematic view of a module including conductive tabs according to some embodiments of the present technology. 
         FIG.  8    shows a schematic elevation view of a module according to some embodiments of the present technology. 
     
    
    
     Several of the figures are included as schematics. It is to be understood that the figures are for illustrative purposes, and are not to be considered of scale or proportion unless specifically stated to be of scale or proportion. Additionally, as schematics, the figures are provided to aid comprehension and may not include all aspects or information compared to realistic representations, and may include exaggerated material for illustrative purposes. 
     In the figures, similar components and/or features may have the same numerical reference label. 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 irrespective of the letter suffix. 
     DETAILED DESCRIPTION 
     Batteries, battery cells, and more generally energy storage devices, are used in a host of different systems. In many devices, the battery cells may be designed with a balance of characteristics in mind. For example, including larger batteries may provide increased usage between charges, however, the larger batteries may require larger housing, or increased space within the device. As device designs and configurations change, especially in efforts to reduce device sizes, the available space for additional battery system components may be constrained. These constraints may include restrictions in available volume as well as the geometry of such a volume. Conventional devices have often been restricted to larger form factors to accommodate both a sufficient battery as well as associated battery system components. The present technology may overcome these issues, however, by providing a configuration by which battery control system components may be confined to a volume accommodating the battery or a battery system in one or more ways. After illustrating an exemplary cell that may be used in embodiments of the present technology, the present disclosure will describe battery system designs having a controlled form factor for use in a variety of devices in which battery cells may be used. 
     Although the remaining portions of the description will reference lithium-ion batteries, it will be readily understood by the skilled artisan that the technology is not so limited. The present techniques may be employed with any number of battery or energy storage devices, including other rechargeable and primary battery types, as well as secondary batteries, or electrochemical capacitors. Moreover, the present technology may be applicable to batteries and energy storage devices used in any number of technologies that may include, without limitation, phones and mobile devices, watches, glasses, bracelets, anklets, and other wearable technology including fitness devices, handheld electronic devices, laptops and other computers, as well as other devices that may benefit from the use of the variously described battery technology. 
       FIG.  1    depicts a schematic cross-sectional view of an energy storage device or battery cell  100  according to embodiments of the present technology. Battery cell  100  may be or include a battery cell, and may be one of a number of cells coupled together to form a battery structure. As would be readily understood, the layers are not shown at any particular scale, and are intended merely to show the possible layers of cell material of one or more cells that may be incorporated into an energy storage device. In some embodiments, as shown in  FIG.  1   , battery cell  100  includes a first current collector  105  and a second current collector  110 . In embodiments one or both of the current collectors may include a metal or a non-metal material, such as a polymer or composite that may include a conductive material. The first current collector  105  and 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 an anode active material  115 , and may be or include copper, stainless steel, or any other suitable metal, as well as a non-metal material including a polymer. The second current collector  110  may be a material selected based on the potential of a cathode active material  120 , and may be or include aluminum, stainless steel, or other suitable metals, as well as a non-metal material including a polymer. In other words, the materials for the first and second current collectors can be selected based on electrochemical compatibility with the anode and cathode active materials used, and may be any material known to be compatible. 
     In some instances the metals or non-metals used in the first and second current collectors may be the same or different. The materials selected for the anode and cathode active materials may be any suitable battery materials operable in rechargeable as well as primary battery designs. For example, the anode active material  115  may be silicon, graphite, carbon, a tin alloy, lithium metal, a lithium-containing material, such as lithium titanium oxide (LTO), or other suitable materials that can form an anode in a battery cell. Additionally, for example, the cathode active material  120  may be a lithium-containing material. 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 can be a lithium iron phosphate, or other suitable materials that can form a cathode in a battery cell. 
     The first and second current collectors as well as the active materials may have any suitable thickness. A separator  125  may be disposed between the electrodes, and may be a polymer film or a material that may allow lithium ions to pass through the structure while not otherwise conducting electricity. Active materials  115  and  120  may additionally include an amount of electrolyte in a completed cell configuration. The electrolyte may be a liquid including one or more salt compounds that have been dissolved in one or more solvents. The salt compounds may include lithium-containing salt compounds in embodiments, 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-metal elements such as phosphorus, and semimetal elements including boron, for example. 
     In some embodiments, the salts may include any lithium-containing material that may be soluble in organic solvents. The solvents included with the lithium-containing salt may be organic solvents, and may include one or more carbonates. For example, the solvents may include one or more carbonates including propylene carbonate, ethylene carbonate, ethyl methyl carbonate, dimethyl carbonate, diethyl carbonate, and fluoroethylene carbonate. Combinations of solvents may be included, and may include for example, propylene carbonate and ethyl methyl carbonate as an exemplary combination. Any other solvent may be included that may enable dissolving the lithium-containing salt or salts as well as other electrolyte component, for example, or may provide useful ionic conductivities, such as greater than or about 5-10 mS/cm. 
     Although illustrated as single layers of electrode material, battery cell  100  may be any number of layers. Although the cell may be composed of one layer each of anode and cathode material as sheets, the layers may also be formed into a jelly roll design, or folded design, prismatic design, or any form such that any number of layers may be included in battery cell  100 . For embodiments which include multiple layers, tab portions of each anode current collector may be coupled together, as may be tab portions of each cathode current collector. Once the cell has been formed, a pouch, housing, or enclosure may be formed about the cell to contain electrolyte and other materials within the cell structure, as will be described below. Terminals may extend from the enclosure to allow electrical coupling of the cell for use in devices, including an anode and cathode terminal. The coupling may be directly connected with a load that may utilize the power, and in some embodiments the battery cell may be coupled with a control module that may monitor and control charging and discharging of the battery cell.  FIG.  1    is included as an exemplary cell that may be incorporated in battery systems according to the present technology. It is to be understood, however, that any number of battery and battery cell designs and materials that may include charging and discharging capabilities similarly may be encompassed by the present technology. 
       FIG.  2    shows a schematic plan view of a battery system  200  according to some embodiments of the present technology. As illustrated, battery system  200  may include a battery cell or battery  205 , which may include any number of battery cells, as well as a battery module  210 . Battery module  210  may be electrically connected with battery  205  to provide a variety of functionality. For example, battery module  210  may monitor battery  205  during charging and discharging operations, and may ensure the battery is not overcharged or over-depleted during use. Additionally, battery module  210  may monitor overall health of the battery  205  to ensure proper functioning. Battery module  210  may couple with terminals of the battery, such as one or both of the positive and negative terminals, in order to provide this functionality. 
     Battery module  210  may also include an additional electrical connector, such as a coupling, that may allow device components to access the battery capacity through the battery module  210 . In this way, battery module  210  may provide a pass-through functionality for delivering power from battery  205 . Consequently, battery module  210  may be under constant load from the battery. Battery  205  may include a battery cell, which may be similar to battery cell  100  described above, and may include a pouch or enclosure to protect the battery cell from exposure to the environment. The housing may also operate to maintain electrolyte and other materials within the battery cell. To access the battery cell through this 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 battery  205 , which may allow the provision of additional materials to protect terminals and conductive components from fluid contact. However, as device configurations continue to shrink, battery designs change, and manufacturing processes incorporate many more small scale operations with smaller and/or thinner materials, these types of incorporations may become less feasible or prone to causing damage. The present technology allows for an adjacent coupling of the battery module  210  onto terminals of the battery  205 , which may further reduce the overall battery system envelope when incorporated within an electronic device. 
       FIG.  3    shows a schematic cross-sectional view of a battery system  300  according to embodiments of the present technology. Battery system  300  may include any of the components previously described, 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 packaging. For example, in some embodiments battery  305  may include a rigid housing, and may include a conductive housing. The conductive housing may be maintained at positive or negative potential in embodiments, and may be maintained at negative potential, which may then operate as a device ground, and be considered similar to a neutral connection. Additionally, by using a rigid housing instead of a flexible pouch, fabrication tolerances on the battery dimensions may be reduced, which may afford increased volume for the internal battery cells, which may provide increased capacity over conventional designs. The rigid housing or can may include a flange  306  extending about the battery  305 , which may be a lid enclosure for the rest of the housing, and which may be or include a seamless or substantially seamless form providing an internal volume in which the battery cell or cells and electrolyte may be contained. 
     Module  310  may monitor and manage aspects of battery  305  operation, and may be a power control module in embodiments. Module  310  may electrically couple with electrode terminals of the battery  305 , and may transfer power through connector  315 , which may be any type of connector, such as a board-to-board connector, for example. In some embodiments, module  310  may not extend beyond the lateral dimensions of battery  305 , and may be maintained within a width of the battery  305 . The connector  315  may be part of a coupling  320 , which may be a flexible coupling extending from the module  310 . For example, connector  315  may be at or near a distal end of the coupling  320 . Coupling  320  may partially extend beyond a lateral dimension of the battery  305  as illustrated, although coupling  320  may be flexible and when incorporated within a device, may be moveable within a particular volume. Module  310 , however, may be fully contained within the lateral width of the battery  305  in some embodiments. Module  310  may include one or more components including a circuit board  312  as well as a mold  314 , which may include a single mold extending about the circuit board  312 , as well as multiple portions in embodiments including discrete portions separately coupled on opposite sides of the circuit board  312 . Coupling  320  may extend from the circuit board and be folded in one or more ways to position the connector  315  beneath the module  310 . Of course, the position may be relative to the orientation of the battery system  300 . 
     For example, battery  305  may have a first surface  307 , which may be a surface adjacent to or facing module  310  in embodiments. Battery  305  may include a second surface  308  from which flange  306  may extend, and battery  305  may include a third surface  309  opposite second surface  308 . First surface  307  may extend between and be partially or substantially normal to second surface  308  and third surface  309 . By substantially is meant that angles may be less than or greater than perfectly perpendicular, which may account for curved surfaces as well as machining or fabrication tolerances. As previously noted, the housing of battery  305  may include a recessed can on which a lid is disposed, and thus in some embodiments first surface  307  and third surface  309  may be part of a continuous structure and may not have a discrete intersection. Similarly, flange  306  may be formed by material extending from the first surface as well as material defining the second surface, such as where first surface  307  may define a lip at an edge along which a lid, being the second surface, may be coupled. Regardless, the flange may extend in line with the second surface in embodiments. 
     Returning to coupling  320 , when folded, connector  315  may be positioned at least partially in line with module  310  along first surface  307  of battery  305 , although the connector  315  may be positioned at least partially between the module  310  and the third surface  309 , as well as at least partially extending past third surface  309  in a direction at least partially along or parallel with the first surface  307  of the battery between the second and third surfaces. The coupling may be a number of flexible couplings including printed circuit board, flex board, or other circuit materials or cables that may allow electrical transmission as well as communication transmission to and from the individual circuit modules or the battery to a system board. 
     The coupling  320  may be folded in multiple ways depending on an electronic device configuration to properly position the connector. For example, in one non-limiting embodiment illustrated, coupling  320  may extend from circuit board  312  in a direction substantially parallel with first surface  307  towards second surface  308 . Again, by substantially is meant the components may not be perfectly parallel with one another, but may generally run in a similar direction, and is to be understood in the same manner throughout the present disclosure. Coupling  320  may include a first fold outward away from battery  305  and over at least a portion of mold  314 , which may return the coupling about 180°. The coupling may then include an arcuate section extending the coupling in plane towards an edge of the module along a longitudinal direction of the module. A second fold may extend the coupling back across the module and towards the first surface of the battery  305 , and return the coupling about 90°. A second arcuate section may extend the coupling in plane in a direction towards the third surface  309  of the battery  305 . A third fold may extend the coupling back along the battery  305  in a direction parallel to the third surface  309 , which may return the coupling about 90°, and which may position the distal end of the coupling with the connector in proper location for connection with a system board or other component. It is to be understood that coupling  320  may take a variety of forms to properly position a connector for coupling depending on location of the component to be connected, and  FIG.  3    illustrates merely one example of a coupling  320  configuration. 
     Adhesive  325  may be included to at least partially hold module  310  against battery  305 . Adhesive  325  may be one of several adhesives incorporated to maintain module  310  with battery  305 , as will be described below in more detail below. 
       FIG.  4    shows a schematic, cross-sectional, partial, top view of battery system  300  according to some embodiments of the present technology. As shown in  FIG.  4   , battery system  300  may include some or all of the components, characteristics, or aspects of battery system  300  described above. For example, battery system  300  in this view shows battery  305  and module  310 . Additional aspects of both the battery  305  and module  310  are shown including multiple locations for electrical and or mechanical coupling of the components. 
     Battery  305  may include one or more terminals extending from battery  305  and providing electrical access to the battery cell. Additionally, a port  402  may be positioned along the first surface  307  of battery  305 . Port  402  may be a fill port or other access to battery  305 , and may be sealed in embodiments. Port  402  may be positioned proximate a lateral edge of battery  305  or first surface  307  of battery  305 , such as near or adjacent a fourth surface  404  of battery  305  that may intersect or extend into a lateral edge of first surface  307  of battery  305 . 
     A first electrode terminal  405  and a second electrode terminal  407  may extend from or be accessible along first surface  307  of battery  305 . In some embodiments each of the first electrode terminal and the second electrode terminal may extend from the first surface  307  of battery  305  to the same position. In some embodiments, such as illustrated, first electrode terminal  405  may extend outward from first surface  307  further than second electrode terminal  407 . As previously noted, in some embodiments the housing of battery  305  may be conductive and may be at the potential of one of the electrodes, such as the anode terminal, although the housing may also be maintained at cathode potential. The second electrode terminal  407  may represent the electrode terminal of the potential at which the housing is maintained. Accordingly, the terminal may be a contact, tab, or access of the housing. The first electrode terminal  405 , however, may be at the opposite potential of the housing and/or the second electrode terminal  407 , and may be maintained or electrically isolated from the rest of the housing. For example, first electrode terminal  405  may be the cathode terminal, although the terminal may also be maintained at anode potential in other embodiments. 
     To isolate the first electrode terminal  405  from the rest of the housing, a spacer  406  may extend circumferentially about the first electrode terminal through the housing of battery  305 , including along the first surface  307  of battery  305 . Consequently, first electrode terminal  405  may extend further than second electrode terminal  407 . In order to limit the extensions of the module to accommodate this configuration, in some embodiments the module  310  may include different conductive tabs to accommodate the spatial offset of the two terminals. In some embodiments, an additional material  409  may further insulate the first electrode terminal. For example, an additional electrically insulative material may be used, such as nylon, or more rigid materials may be included such as aramid polymer materials, including Nomex, or any other electrically insulative material may be used, for example. 
     Module  310  may be electrically coupled with battery  305  at both the first electrode terminal and the second electrode terminal. As noted, module  310  may include a circuit board  312  as well as a mold. The circuit board  312  may be characterized by a first surface  413  and a second surface  414  opposite the first surface. A first contact  415  and a second contact  417  may be included on first surface  413  to electrically couple the module with the battery  305 . Extending between and electrically coupling the first contact  415  with the first electrode terminal  405  may be a first conductive tab  418 . Extending between and electrically coupling the second contact  417  with the second electrode terminal  407  may be a second conductive tab  420 . These connections will be described in further detail below. 
     Module  310  may also include a mold  314  which may extend about the circuit board  312  in embodiments. In some embodiments as illustrated, mold  314  may include two discrete molds extending separately from the first surface and second surface of the circuit board. For example, first mold  422  may include a first surface  423  and a second surface  424  coupled with the first surface  413  of the circuit board. First mold  422  may extend from the circuit board  312  towards the battery  305  or towards the first surface  307  of battery  305  in some embodiments. Second mold  425  may include a first surface  426  and a second surface  427  coupled with the second surface  414  of the circuit board. 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, and which are encapsulated by one or both of the first mold  422  and the second mold  425 . For example, electronic device  430   a  and  430   b  are illustrated as extending from the second surface  414  of circuit board  312 . The devices  430  are encapsulated by second mold  425 , which may provide protection for the electronic devices. 
     First mold  422  may be characterized by one or more features to accommodate the components of the battery  305  as well as the coupling of the module  310  with the battery  305 . For example, first mold  422  may define a recess  432  in first surface  423  of the first mold  422 . Recess  432  may extend partially along first surface  423  of the first mold  422 , and may extend along a portion of first mold  422  proximate or facing the first electrode terminal  405  and/or the second electrode terminal  407  of battery  305 . First contact  415  and second contact  417  may be located or accessed through recess  432 . As illustrated, recess  432  may allow closer coupling of the module  310  with the battery  305  by creating a void space within first mold  422  and in which the first electrode terminal may extend. First electrode terminal  405  may extend from an interior of battery  305  to an exterior location, and may be electrically isolated as well as physically isolated from contacting battery  305  housing with spacer  406 . The exterior portion of first electrode terminal  405  may be at least partially positioned within recess  432  or the space created by recess  432 . 
     First mold  422  may also include a feature to accommodate port  402 . As illustrated, port  402  may in some embodiments at least partially extend beyond first surface  307  of battery  305 . First mold  422  may define a recessed ledge  434  in the first surface  423  of the first mold. Recessed ledge  434  may be a recess similar to recess  432  in embodiments, or may be a recessed ledge as illustrated, which may extend the recession from the defined recessed ledge  434  towards a lateral edge of the first mold proximate the port. By incorporating features such as recess  432  and recessed ledge  434 , module  310  may better accommodate an uneven profile of components along first surface  307  of battery  305 , while maintaining a substantially even exterior profile, such as along first surface  426  of second mold  425 . 
     As noted above, multiple adhesives may be included both for component protection and positioning. In addition to external adhesive  325  described previously, one or more adhesives may be included between the module  310  and battery  305  in embodiments. A first adhesive  435  may be positioned between the first surface  307  of the battery  305  and the first mold  422  in embodiments. As illustrated, first adhesive  435  may couple first mold  422  with at least a portion of first surface  307  of battery  305 . First adhesive  435  may extend directly across port  402  in some embodiments. First adhesive  435  may also extend across recessed ledge  434 , and may extend towards, up to, or at least partially beyond a location of first mold  422  where recess  432  is defined in first surface  423  of the first mold. 
     Turning to  FIG.  5    is shown a schematic partial side elevation view of battery system  300  according to some embodiments of the present technology. As shown in  FIG.  5   , battery system  300  may include some or all of the components, characteristics, or aspects of battery system  300  described previously. For example, battery system  300  in this view shows battery  305  and module  310 . Additional aspects of both the battery  305  and module  310  are shown including coupling between the second electrode terminal  407  and the second conductive tab  420  of module  310 . 
     Second electrode terminal  407  may be substantially flush or even slightly recessed from first surface  307  of battery  305 . Because module  310  may be positioned to accommodate the extended portion of first electrode terminal  405 , a gap may exist in some embodiments between the second contact  417  on module  310  and the second electrode terminal  407 . Accordingly, in some embodiments, second conductive tab  420  may extend across the gap. Second conductive tab  420  may be coupled to module  310  at a first end  521  of second conductive tab  420 . The coupling may be by a weld, conductive adhesive, or other conductive coupling allowing or facilitating electrical transfer between second conductive tab  420  and second contact  417  of module  310 . Second conductive tab  420  may extend from first end  521  along a length of the conductive tab to a distal or second end  522 . Second end  522  may be coupled with second electrode terminal  407 , and may also be coupled via weld, adhesive, or any other coupling allowing electrical communication between the components. From first end  521 , second conductive tab  420  may extend relatively or substantially parallel to a plane of the second contact  417  and/or the second electrode terminal  407 . Second end  522  may be fixedly coupled with second electrode terminal  407 , and may also be relatively or substantially parallel to a plane of the second contact  417  and/or the second electrode terminal  407 . 
     From first end  521  to second end  522 , second conductive tab  420  may be characterized by an amount of curvature or by a number of bends to at least partially define a volume  525  bounded between the first end  521  and the second end  522  of the second conductive tab  420 . Second conductive tab  420  may be a relatively thin conductive material, and thus, may have limited rigidity against compression or deformation within an electrode device. In some embodiments, a spacer  530  may be seated or positioned in the volume between the first end  521  and the second end  522  of the second conductive tab  420 . The spacer may be formed of an insulative material, and may include adhesive on opposite sides of the spacer material. Accordingly, the spacer  530  may be adhered to both the first end  521  of the second conductive tab  420  as well as the second end  522  of the second conductive tab  420  on surfaces opposite surfaces coupled respectively with the second contact  417  and the second electrode terminal  407 . Spacer  530  may extend laterally to a width similar to, less than, or greater than the conductive tab, including either end of the conductive tab as will be described further below. 
       FIG.  5    also illustrates features of the first mold  422  and the second mold  425  as coupled with the circuit board  312 . In some embodiments, circuit board  312  extends substantially parallel to the first surface  307  of battery  305 . Circuit board  312  may extend towards or to, or substantially even with, flange  306 , which as noted previously may be a planar extension from second surface  308 , and may extend proud of first surface  307  of battery  305 . A gap may be maintained between an exterior edge of flange  306  and first surface  413  of circuit board  312 . Second mold  425 , which may be coupled with second surface  414  of circuit board  312 , may extend fully along circuit board  312  parallel to first surface  307  in a direction extending towards surface  308 . Second mold  425  may extend to edge  535  of circuit board  312 , which may be an outer edge of the circuit board proximate, adjacent, or in line with, flange  306 . 
     First mold  422  may not extend fully along first surface  413  of circuit board  312  to prevent contact with flange  306  in embodiments. As illustrated, first mold  422  may be offset from edge  535  of circuit board  312  in a direction parallel to the first surface  307  of battery  305 . First mold  422  may extend past the flange towards the battery in some embodiments, while limiting or being free of any contact with flange  306 . For example, an exterior edge of flange  306  may define a plane parallel to the first surface  307  of battery  305 , and first mold  422  may extend through this plane towards first surface  307  of battery  305 . 
       FIG.  5    further illustrates an indentation  540  along battery  305  along the intersection of first surface  307  and third surface  309 . As noted above, the housing of battery  305  may include a bowl-and-lid type housing, and thus an at least partial continuity may exist between first surface  307  and third surface  309 , which may otherwise extend normal to first surface  307 . Where the surfaces intersect, an indentation  540  may be formed inward towards an internal battery cell of the battery  305 . The indentation  540  may at least partially accommodate connector  315 , or the associated connector or component with which connector  315  is coupled. 
       FIG.  6    shows a schematic partial, cross-sectional, elevation view along line A-A of  FIG.  3    of battery system  300  according to some embodiments of the present technology. As shown in  FIG.  6   , battery system  300  may include some or all of the components, characteristics, or aspects of battery system  300  described previously. For example, battery system  300  in this view shows battery  305  and module  310 . Additional aspects of both the battery  305  and module  310  are shown including coupling between the first electrode terminal  405  and the first conductive tab  418  of module  310 . 
     Within battery  305  is cell material  605 , which may be one or more battery cells as described previously. A conductive extension  610  may electrically couple one or more current collectors or electrodes with first electrode terminal  405 . For example, in embodiments where first electrode terminal is a cathode terminal, conductive extension  610  may electrically couple cathode materials of cell material  605  with first electrode terminal  405 . Spacer  406  may electrically insulate first electrode terminal  405  from the rest of the housing of battery  305  in embodiments where the housing may be at the opposite electrode potential. Both spacer  406  and first electrode terminal  405  may extend through the housing of battery  305 . First conductive tab  418  may extend between first contact  415  and the first electrode terminal  405 . First conductive tab  418  may be folded in some embodiments. The fold may facilitate connections in some embodiments. For example, the first conductive tab  418  may be coupled with first contact  415  by any of the coupling described previously. The first conductive tab  418  may be at least partially folded in some embodiments, and coupled with the first electrode terminal by similar coupling mechanisms. After the first conductive tab and second conductive tab have both been connected with battery  305 , the module may be rotated into position forming the bend or fold in first conductive tab  418 . 
     Additional features of adhesive  325  are also illustrated in  FIG.  6   . Adhesive  325  may extend about the module  310 , contacting both the first conductive tab  418  and the battery  305 . A first end of adhesive  325  may extend within the fold of conductive tab  418 , and contact a first end of conductive tab  418  coupled with first contact  415 . The adhesive may then extend around edge  535  of circuit board  312  and about second mold  425 . The adhesive may then extend along indentation  540  and to third surface  309  of battery  305 . Adhesive  325 , 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. While in some embodiments the adhesives are water resistant, in other embodiments the adhesives may be configured to simply protect the components from any environmental contaminants including dust, lint, or other particulates, and insulate the components against contact. Additionally, the adhesives may be configured to maintain a location of the module  310  relative to the battery  305 . The adhesives may be or include a polymer backing with an applied adhesive. The polymer may be any number of polymers that provide electrical resistivity, structural resiliency, hydrophobicity, or flexibility. For example, in some embodiments a polyimide-backed tape may be used, which may afford a thin film tape that may be flexible to accommodate the topography of module  310 , while limiting gaps or spacing about the module. Although described as a tape, additional adhesives, encapsulants, and enclosures may be utilized to provide a similar protection to components of the module  310 , and are similarly encompassed by the present technology. 
     Second mold  425  may be characterized by chamfered corners  615  on one or more edges of the mold material in some embodiments. A first corner  615   a  may be chamfered and/or a second corner  615   b  may be chamfered. The chamfered edges may provide an additional reduction in the outer envelope or volume consumed by the module  310 . An additional insulation  620  or spacer may be included between the adhesive  325  and a second edge  635  of circuit board  312 , which may also extend to indentation  540 . The insulation  620  may accommodate any surface irregularities or external components, including the connector, that may puncture the adhesive, as well as assist in accommodating the topography of the battery  305 . 
     The internal view of battery  305  additionally illustrates the limited impact of indentation  540  on the battery cell material  605 . Because of the additional internal components proximate first surface  307  of battery  305 , the indentation may be produced to limit interference with the battery cell material  605 . For example, an additional internal spacer  625  may be formed to contour to the indentation, and the indentation may be formed to end proximate a location of third surface  309  where battery cell material  605  may reside. Accordingly, battery  305  may provide a configuration that limits impact with connector  315  as described above, while also limiting or preventing any reduction in available volume for battery cell material  605 . 
       FIG.  7    shows a schematic view of a module  700  including conductive tabs according to some embodiments of the present technology. Module  700  illustrates exemplary conductive tabs according to some embodiments of the present technology. It is to be understood that any number of conductive materials or tab geometries may be used in the present technology, and thus the example of module  700  is not intended to limit the present technology. Module  700  may include some or any of the components of module  310  described above, and may include a circuit board  712 . Circuit board  712  may include a first contact  715  and a second contact  717 , which may be electrically coupled with electrode terminals on a battery as previously described. A first conductive tab  718  may be coupled with and extend from first contact  715 , and a second conductive tab  720  may be coupled with and extend from second contact  717 . 
     The conductive tabs may include a variety of geometries providing a surface for coupling with electrode tabs of a battery. Although conductive tabs  718  and  720  may be rectangular, in some embodiments the conductive tabs may be characterized by any number of geometries that may be shaped to accommodate contacts or terminals of virtually any shape. A first end and second end of each conductive tab may be or form a weld tab, which may provide a landing space and surface to which electrode tabs may be welded, bonded, or otherwise adhered to an associated contact or terminal. The conductive tabs may also include an extension portion between the first end and second ends of the conductive tabs. 
     Extension portions  722 ,  725  may include one or more notches, regions, thicknesses, or widths along a length of the extension portion. The extension portions may be shaped or configured to facilitate bending, folding, or manipulation of the conductive tabs to improve a contact surface position for the weld tab, as well as to limit sheering or other forces on the conductive tab. For example, extension portion  725  of conductive tab  720  may include sets of notches to facilitate bending, as well as an interior region between the sets of notches, which may extend across a gap length between a contact and terminal as described previously. A spacer may be seated on or within this interior region, such as to produce second conductive tab  420  described previously. Additionally, the end portions of the conductive tabs may be of different shapes or sizes in embodiments. For example, although the contacts may be of similar size, a battery terminal may be larger or smaller than a circuit board contact in some embodiments. Accordingly, a first end  730  of a conductive tab  720 , may be sized to accommodate a contact  717  of the circuit board, while a second end  732  of the conductive tab  720 , may be sized to accommodate an electrode terminal of a battery. Hence, any number of variations may be provided by the present technology to accommodate both modules and batteries. 
       FIG.  8    shows a schematic elevation view of a module  800  according to some embodiments of the present technology. Module  800  may include any of the features or aspects of module  310  described elsewhere, and may illustrate a view of module  310  separated from battery  305 , for example. Module  800  may illustrate how a first mold may be offset from an edge of the circuit board to accommodate a flange protruding from the battery towards the circuit board. Module  800  illustrates a first contact  415  and a second contact  417  exposed on circuit board  312 . First mold  422  may extend about these contacts to encapsulate or otherwise protect circuit board  312  as well as components or devices on circuit board  312 . A first conductive tab  418  may be coupled with first contact  415 , and a second conductive tab  420  may be coupled with second contact  417 . The conductive tabs are illustrated in partially folded position, or in L-shaped configurations that may facilitate connection with a battery. First mold  422  may extend about the contacts, and may extend towards an edge  535  of circuit board  312 , while maintaining an amount of offset to limit or prevent interaction between first mold  422  and a flange of the battery to which the module  800  may be coupled. The offset may be sized to accommodate a thickness of the flange as well as the manufacturing tolerances associated with module coupling. 
     Battery systems according to embodiments of the present technology may provide a limited footprint extension for a control module associated with a battery. Because many electronic devices have limited volume for a battery, the present technology allows more of this volume to be used for battery cell material, which may increase or maintain battery capacity in smaller devices. Additionally, while many battery configurations are characterized by uneven external topographies, modules according to some embodiments of the present technology may maintain a substantially even external surface by providing internal mold and component configurations that accommodate the uneven battery characteristics. 
     In the preceding description, for the purposes of explanation, numerous details have been set forth in order to provide an understanding of various embodiments of the present technology. It will be apparent to one skilled in the art, however, that certain embodiments may be practiced without some of these details, or with additional details. 
     Having disclosed several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the embodiments. Additionally, a number of well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present technology. Accordingly, the above description should not be taken as limiting the scope of the technology. 
     Where a range of values is provided, it is understood that each intervening value, to the smallest fraction of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Any narrower range between any stated values or unstated intervening values in a stated range and any other stated or intervening value in that stated range is encompassed. The upper and lower limits of those smaller ranges may independently be included 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, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included. Where multiple values are provided in a list, any range encompassing or based on any of those values is 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 “the cell” includes reference to one or more cells and equivalents thereof known to those skilled in the art, and so forth. 
     Also, the words “comprise(s)”, “comprising”, “contain(s)”, “containing”, “include(s)”, and “including”, when used in this specification and in 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.

Metadata:
Filing Date: 20200521
Publication Date: 20230110
Grant Date: 20230110
Priority Date: 20190530
Inventors: BALARAM, HARAN
BOHNEY, NATHAN J.
WILSON, JONATHAN C.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M10/4257", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2010/4271", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/425", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/4257", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2010/4271", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/50", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 73549745