PATENT DOCUMENT

Publication Number: US-10559786-B2
Application Number: US-201715795877-A
Country: US
Kind Code: B2

Title: Cell packaging techniques

Abstract:
Battery systems according to embodiments of the present technology may include a battery cell having an electrode tab extending from an edge of the battery cell. The systems may also include a module electrically coupled with the battery cell. The module may be characterized by a first surface, a height, and a second surface opposite the first surface. A conductive tab coupled along the first surface of the module may extend from a first end parallel to a plane of the first surface. The conductive tab may be characterized by a curvature proximate a midpoint of the conductive tab. A distal region of the conductive tab may return back across the first surface of the module substantially parallel to the first surface. A distal portion of the electrode tab may be fixedly coupled with the distal region of the conductive tab.

Claims:
What is claimed is: 
     
       1. A battery system comprising:
 a battery cell, wherein the battery cell comprises an electrode tab extending from an edge of the battery cell; and 
 a module electrically coupled with the battery cell, wherein:
 the module is characterized by a first surface, a height, and a second surface opposite the first surface, 
 a conductive tab coupled along the first surface of the module extends from a first end parallel to a plane of the first surface, 
 the conductive tab is characterized by a curvature at a midpoint of the conductive tab, 
 a distal region of the conductive tab returns back across the first surface of the module parallel to the first surface, and 
 a distal portion of the electrode tab is fixedly coupled with the distal region of the conductive tab; and 
 
 a first water resistant tape extending about the module and across the first end of the conductive tab. 
 
     
     
       2. The battery system of  claim 1 , wherein the module comprises a circuit board including components extending from a surface of the circuit board. 
     
     
       3. The battery system of  claim 2 , wherein the module further comprises a spacer extending from the second surface of the module to the first surface of the module, and wherein the spacer defines a cavity into which the components extending from the surface of the circuit board are positioned. 
     
     
       4. The battery system of  claim 3 , wherein the spacer includes an adhesive coupling the spacer with the circuit board. 
     
     
       5. The battery system of  claim 3 , wherein the spacer is characterized by an increased thickness on opposite sides of the spacer extending from the second surface to the first surface. 
     
     
       6. The battery system of  claim 3 , wherein the module further comprises a pottant within the cavity and encapsulating the components extending from the surface of the circuit board. 
     
     
       7. The battery system of  claim 1 , further comprising a second water resistant tape extending across the distal portion of the electrode tab and contacting the first water resistant tape at the first surface of the module. 
     
     
       8. The battery system of  claim 7 , wherein the second water resistant tape extends about an interior side of the module and along the second surface of the module. 
     
     
       9. A battery system comprising:
 a battery cell, wherein the battery cell comprises an electrode tab extending from an edge of the battery cell; 
 a module electrically coupled with the battery cell, the module comprising a circuit board including components extending from a surface of the circuit board, wherein:
 the module is characterized by a first surface, a height, and a second surface opposite the first surface, 
 a conductive tab coupled along the first surface of the module extends from a first end parallel to a plane of the first surface, 
 the conductive tab is characterized by a curvature at a midpoint of the conductive tab, 
 a distal region of the conductive tab returns back across the first surface of the module parallel to the first surface, and 
 a distal portion of the electrode tab is fixedly coupled with the distal region of the conductive tab; and 
 
 a spacer extending from the second surface of the module to the first surface of the module, and wherein the spacer defines a cavity into which the components extending from the surface of the circuit board are positioned; and 
 a pottant within the cavity and encapsulating the components extending from the surface of the circuit board. 
 
     
     
       10. The battery system of  claim 9 , wherein the spacer includes an adhesive coupling the spacer with the circuit board. 
     
     
       11. The battery system of  claim 9 , wherein the spacer is characterized by an increased thickness on opposite sides of the spacer extending from the second surface to the first surface. 
     
     
       12. The battery system of  claim 9 , further comprising a first water resistant tape extending about the module and across the first end of the conductive tab. 
     
     
       13. The battery system of  claim 12 , further comprising a second water resistant tape extending across the distal portion of the electrode tab and contacting the first water resistant tape at the first surface of the module. 
     
     
       14. The battery system of  claim 13 , wherein the second water resistant tape extends about an interior side of the module and along the second surface of the module. 
     
     
       15. A battery system comprising:
 a battery cell, wherein the battery cell comprises an electrode tab extending from an edge of the battery cell; and 
 a module electrically coupled with the battery cell, wherein:
 the module is characterized by a first surface, a height, and a second surface opposite the first surface, 
 a conductive tab coupled along the first surface of the module extends from a first end parallel to a plane of the first surface, 
 the conductive tab is characterized by a curvature at a midpoint of the conductive tab, 
 a distal region of the conductive tab returns back across the first surface of the module parallel to the first surface, and 
 a distal portion of the electrode tab is fixedly coupled with the distal region of the conductive tab; and 
 
 a first water resistant tape extending about the module and across the first end of the conductive tab; and 
 a second water resistant tape extending across the distal portion of the electrode tab and contacting the first water resistant tape at the first surface of the module. 
 
     
     
       16. The battery system of  claim 15 , wherein the module comprises a circuit board including components extending from a surface of the circuit board. 
     
     
       17. The battery system of  claim 16 , wherein the module further comprises a spacer extending from the second surface of the module to the first surface of the module, and wherein the spacer defines a cavity into which the components extending from the surface of the circuit board are positioned. 
     
     
       18. The battery system of  claim 17 , wherein the spacer includes an adhesive coupling the spacer with the circuit board. 
     
     
       19. The battery system of  claim 17 , wherein the spacer is characterized by an increased thickness on opposite sides of the spacer extending from the second surface to the first surface. 
     
     
       20. The battery system of  claim 17 , wherein the module further comprises a pottant within the cavity and encapsulating the components extending from the surface of the circuit board. 
     
     
       21. The battery system of  claim 15 , wherein the second water resistant tape extends about an interior side of the module and along the second surface of the module.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     The application claims the benefit of U.S. Application Ser. No. 62/555,464 filed Sep. 7, 2017, the entire disclosure of which is hereby incorporated by reference for all purposes. 
    
    
     TECHNICAL FIELD 
     The present technology relates to battery systems. More specifically, the present technology relates to battery component coupling to produce more robust designs 
     BACKGROUND 
     Batteries are used in many devices. Portable devices may present more opportunity for water or environmental materials to come in contact with battery components, which may cause malfunction or failure. 
     SUMMARY 
     Battery systems according to embodiments of the present technology may include a battery cell having an electrode tab extending from an edge of the battery cell. The systems may also include a module electrically coupled with the battery cell. The module may be characterized by a first surface, a height, and a second surface opposite the first surface. A conductive tab coupled along the first surface of the module may extend from a first end parallel to a plane of the first surface. The conductive tab may be characterized by a curvature proximate a midpoint of the conductive tab. A distal region of the conductive tab may return back across the first surface of the module substantially parallel to the first surface. A distal portion of the electrode tab may be fixedly coupled with the distal region of the conductive tab. 
     In some embodiments, the module includes a circuit board having components extending from a surface of the circuit board. The module may also include a spacer extending from the second surface of the module to the first surface of the module. The spacer may define a cavity into which the components extending from the surface of the circuit board may be positioned. The spacer may include an adhesive coupling the spacer with the circuit board. The spacer may be characterized by an increased thickness on opposite sides of the spacer extending from the second surface to the first surface. The module may also include a pottant within the cavity and encapsulating the components extending from the surface of the circuit board. The module may include a first water resistant tape extending about the module and across the first end of the conductive tab. The system may also include a second water resistant tape extending across the distal portion of the electrode tab and contacting the first water resistant tape at the first surface of the module. The second water resistant tape may extend about an interior side of the module and along the second surface of the module. 
     The present technology also encompasses additional battery systems. The systems may include a battery cell having an electrode tab extending from an edge of the battery cell. The systems may include a bracket extending laterally from the battery cell and supporting the electrode tab. The systems may include a module seated above a second surface of the electrode tab opposite a first surface of the electrode tab. The module may include a conductive tab electrically coupled with the electrode tab. The systems may also include an environmental tape substantially encompassing the module and extending towards the battery cell and contacting at least a portion of the bracket. The systems may include a seating tape positioned between the module and the second surface of the electrode tab. The environmental tape may contact the seating tape along a surface of the seating tape. The module may include a circuit board characterized by a first surface adjacent the conductive tab and a second surface opposite the first. The circuit board may include electrical components extending from the second surface. The module may also include a spacer extending from a second surface of the module to a first surface of the module opposite the second surface of the module. The spacer may define a cavity into which the components extending from the second surface of the circuit board are positioned. 
     The present technology also encompasses multi-cell batteries. The systems may include a first battery cell having a first electrode tab extending from a first end of the first battery cell. The systems may include a second battery cell positioned adjacent the first end of the first battery cell. The second battery cell may extend perpendicular to the first battery cell, and the second battery cell may include a second electrode tab extending from a first end of the second battery cell. The systems may include a power module comprising a flexible circuit material including a first portion extending in a first direction along the first battery cell. The power module may include a second portion extending in a second direction substantially normal to the first direction along the second battery cell. The power module may include a first circuit module extending parallel to the first end of the first battery cell and electrically coupled with the first electrode tab. The power module may also include a second circuit module extending parallel to the first end of the second battery cell and electrically coupled with the second electrode tab. 
     In some embodiments, the first circuit module may extend normal to the first portion of the power module. The second circuit module may extend normal to the second portion of the power module. The power module may include a power tab extending from a first side of the power module opposite a second side of the power module from which the first circuit module and the second circuit module extend. The flexible circuit material may include a first rigid section including the first portion of the power module, and may include a second rigid section including the second portion of the power module. The flexible circuit material may include a flexible joint coupling the first rigid section and the second rigid section. The systems may also include a bracket in which the first battery cell and the second battery cell are seated. The bracket may include a first section extending along a portion of the first electrode tab, and may include a second section extending along a portion of the second electrode tab. The bracket may include a sidewall extending between the first battery cell and the first portion of the power module. 
     Such technology may provide numerous benefits over conventional technology. For example, the present systems may limit water ingress to the battery cell structure. Additionally, the present systems may increase the battery cell and module protection against environmental contaminants. 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 cross-sectional view of a battery system according to embodiments of the present technology. 
         FIGS. 4A-4C  show schematic views of a battery system module according to embodiments of the present technology. 
         FIG. 5  shows a schematic plan view of a battery system according to embodiments of the present technology. 
         FIG. 6  shows a schematic perspective view of a battery system control module according to 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 unless specifically stated to be of scale. 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. Many portable devices may be exposed to water, dust, or other environmental contaminants from being dropped, opened, submerged, or otherwise exposed to everyday environments. Conventional technologies attempt to improve device seals, or packaging of the battery itself. However, terminals of the battery often remain exposed, which can lead to corrosion or a point of ingress for water or contaminants over time. The present technology overcomes these issues with novel packaging that more securely covers terminals and cell access locations. Additionally, the present technology provides new power module designs for coupling multiple battery cells within a reduced space. After illustrating an exemplary cell that may be used in embodiments of the present technology, the present disclosure includes power module designs and battery system designs for use in a variety of devices in which battery cells may be used. 
     Although the remaining portions of the description will routinely 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 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, handheld electronic devices, laptops and other computers, as well as other devices that may benefit from the use of rechargeable battery technology. 
       FIG. 1  depicts a schematic cross-sectional view of an energy storage device  100  according to embodiments of the present technology. Energy storage device  100  may be or include a battery cell, and may include 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 the energy storage device  100 . 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. 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 , such as 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 , such as 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. 
     The first and second current collectors may be made of any material known in the art. For example, copper, aluminum, nickel, or stainless steel may be used, as well as composite materials having metallic aspects, and non-metallic materials including polymers. In some instances the metals or non-metals used in the first and second current collector may be the same or different. The materials selected for the anode and cathode active materials may be any suitable battery materials. 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 its 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, cell material  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 cell material  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 or enclosure may be formed about the cell to contain electrolyte and other materials within the cell structure. Terminals may extend from the pouch to allow electrical coupling of the cell for use in devices. The coupling may be directly to 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. 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  205 , as well as a battery module  210 . Battery module  210  may be electrically connected to battery  205  to provide a variety of functionality. For example, battery module  210  may monitor battery cell  205  during charging and discharging operations, and may ensure the battery cell is not overcharged or over depleted during use. Additionally, battery module  210  may monitor overall health of the battery cell  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 provide access to an additional electrical connector that may allow device components to access the battery storage through the battery module  210 . In this way, battery module  210  may provide a pass-through functionality for delivering power from battery cell  205 . Consequently, battery module  210  may be under constant load from the battery cell, and may provide multiple locations for contaminants that may affect functionality, or for water ingress to electrically conductive portions of the battery. Should water permeate into the battery cell  205 , the battery system  200  may malfunction or fail. 
     Battery cell  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 pouch may also operate to maintain electrolyte and other materials within the battery cell. To access the battery cell through this pouch, one or more terminals or leads may extend through the pouch. Although a variety of sealing materials or techniques may be used to secure this access, should the terminal corrode over time, it may eventually provide a path into the battery cell for water, which may cause the cell to fail. When battery cell  205  is included in a device, such as a mobile phone, for example, if the device is dropped in liquid, the liquid may enter the device housing. Once within the housing, the liquid may be in contact with the battery cell or terminals if not protected. Additionally, as the battery cycles, heat is generated that may produce vapor within the device housing from the liquid. Water vapor contained within the device may also corrode conductive terminals, or may seep through insufficiently secured terminal penetrations. Additionally, dust or environmental particulates may accumulate across aspects of the battery system, which may produce potential short circuit paths. The present technology may include materials and designs to reduce or limit contaminant and water access to the terminals as will be described further below. 
       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 cell  305 , and a module  310 . Battery cell  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. Module  310  may monitor and manage aspects of battery cell  305  operation, and may be a power control module in embodiments. 
     Battery cell  305  may include one or more terminals or electrode tabs  307  extending from battery cell  305  for providing electrical access to the battery cell. A sealant  309  may be formed or disposed about electrode tab  307  where it penetrates battery cell  305 . Electrode tab  307  may extend from an edge or side of battery cell  305 . Module  310  may be electrically coupled with battery cell  305  through electrode tab  307 . The module  310  may be characterized by a first surface  312  and a second surface  314  opposite the first surface. Module  310  may also be characterized by a height between the first surface  312  and the second surface  314 . Coupled along first surface  312  may be a conductive tab  315 . Conductive tab  315  may be electrically coupled with electrode tab  307  to access and monitor battery cell  305 . 
     Battery system  300  may provide a number of access locations for water ingress into the battery cell  305  of the system, which may cause corrosion or damage to one or more components if not adequately protected. For example, in addition to where electrode tab  307  extends through the enclosure of battery cell  305 , where electrode tab  307  couples with conductive tab  315  and where conductive tab  315  couples with module  310  may provide additional locations for potential corrosion. Accordingly, battery system  300  may include a configuration and coupling design to reduce the possibility of water ingress or access to conductive or other corrodible materials. 
     Conductive tab  315  may be coupled to module  310  along the first surface  312  of module  310 . Conductive tab  315  may be coupled with the first surface  312  at a first end  317  of conductive tab  315 . The coupling may be by a weld, conductive adhesive, or other conductive coupling allowing or facilitating electrical transfer between conductive tab  315  and module  310 . Conductive tab  315  may extend from first end  317  along a length to a second end  319 . From first end  317 , conductive tab  315  may extend relatively or substantially parallel to a plane of first surface  312  of module  310 . Second end  319  may also extend relatively or substantially parallel to the plane of first surface  312 , and may be fixedly coupled with electrode tab  315  along a distal region of conductive tab  315  with a distal portion of electrode tab  307 , such as an end portion  308 . Conductive tab  315  and electrode tab  307  may also be coupled via weld, adhesive, or any other coupling allowing electrical communication between the components. 
     Proximate a midpoint of conductive tab  315 , conductive tab  315  may be characterized by a curvature or fold of the tab. The fold  320  may allow a distal region of conductive tab  315 , such as second end  319 , to extend back across the first surface  312  of module  310  substantially parallel to the first surface  312  and the first end  317  of conductive tab  315 . By including a fold in conductive tab  315 , a surface may be provided across the second end  319  of conductive tab  315  for coupling electrode tab  307 . Electrode tab  307  may be a more robust component than conductive tab  315  in some embodiments. For example, electrode tab may be thicker than conductive tab  315 , and may provide additional support and protection to battery module  310 . Battery system  300  may be used in any number of devices, including mobile devices that may be dropped, bumped, or otherwise jostled, which may affect interior components. As devices shrink, spacing within a device may also reduce, which may place multiple components in close proximity within the device. These components, which may include circuit boards, circuit components, circuit couplings, and other materials, may include sharp corners, or other features that may damage other components in close proximity. Battery module  310  may be a relatively fragile component, or may include fragile components within the structure. The coupling of battery cell  305  and module  310  may be performed to provide additional protection of the module and included components. 
     For example, as illustrated, in some embodiments electrode tab  307  may extend about module  310  on one or more sides. Module  310  may be seated on electrode tab  307 . Module  310  may be at least partially adhered to electrode tab  307  along second surface  314  of module  310 . For example, seating tape  322  may be included along a surface of electrode tab  307 , and module  310  may contact seating tape  322  along second surface  314 . Seating tape  322  may include adhesive on one or two surfaces, to couple with electrode tab  307 , and optionally couple with module  310  as well in some embodiments. Seating tape  322  may include an amount of cushion or thickness to afford compression or flexibility for movement and protection of module  310 . 
     Electrode tab  307  may be characterized by an arcuate shape that extends up a side of module  310  and curves towards end portion  308 , which may be coupled with conductive tab  315 . Electrode tab  315  may extend from battery cell  305  substantially parallel to first surface  312  of module  310 , before turning orthogonally up a height of module  310 , and then extending back across module  310  and again substantially parallel to first surface  312 , with second end  319  of conductive tab  315  positioned between the first surface  312  of module  310  and the end  308  of electrode tab  307 . This extension of electrode tab  307  may provide protection about an otherwise exposed side  316  of module  310  opposite an internal sidewall  318 , as well as above and below module  310  as it is positioned relative to the battery cell  305 . By configuring conductive tab  315  and electrode tab  307  to end parallel to first surface  312  of module  310 , an exterior profile of module  310  as coupled with battery cell  305  may be characterized by substantially rounded corners and continuous side surfaces of the device. 
     Module  310  may include a number of components for protection and control over operations of battery cell  305 . For example, module  310  may include a circuit board  325 , which may include one or more components  330  extending from a surface of circuit board  325 . Circuit board  325  may include a first surface  326  proximate or adjacent first surface  312  of module  310 , and a second surface  327  opposite the first surface  326 . In some embodiments, components  330  may extend from second surface  327  of circuit board  325 , and may extend away from first surface  312  of module  310 . Module  310  may include materials to protect components  330  from device abuse and potential water ingress by including them within a cavity  335  included within module  310 . Cavity  335  may be filled with a pottant  338  configured to encapsulate components  330 . The pottant  338  may be injected or applied during manufacturing to conformally coat the components and provide protection both to drop events as well as to water ingress. By utilizing pottant  338 , components  330  may be substantially or essentially contained to limit the possibility of water or other liquid contact to the components  330 . 
     Module  310  may include a spacer  340  that extends from second surface  314  up to or towards first surface  312  of module  310 . Spacer  340  may be or include a plastic or other insulative material that provides additional crush protection for module  310 . Spacer  340  may at least partially define cavity  335  within module  310  within or into which the components  330  may extend. Spacer  340  may include an adhesive along a surface of the spacer  340  to couple with circuit board  325 , or may include a snap coupling about one or more locating features of the circuit board as will be discussed further below. Spacer  340  may also be characterized by an increased thickness on opposite sides of the module  310  proximate external side  316  and internal side  318  of the module  310 . The increased thickness may be included along regions of the spacer  340  extending from second surface  314  to first surface  312  of module  310 . Spacer  340  may be included to provide protection both during assembly and during events such as device drops for components  330 . Spacer  340  may be made from a number of materials including foams, plastics, rubbers, and other insulating materials. Spacer  340  may be rigid, although in some embodiments spacer  340  includes an amount of flexibility or compression to withstand and protect components  330  during drop or abuse events of devices in which battery system  300  may be included. 
     To protect each of the conductive components, battery system  300  may include one or more layers of additional environmental protection. Module  310  may include an environmental protective tape, such as a first water resistant tape  350  extending about module  310 , and at least partially covering first surface  312 , second surface  314 , interior sidewall  318  and external sidewall  316 . While in some embodiments the tape is water resistant, in other embodiments the tape may be configured to simply protect the components from any environmental contaminants including dust, lint, or other particulates. The first water resistant tape  350  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, and 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. First water resistant tape  350  may extend across first surface  312 , and may at least partially cover conductive tabs  315 . For example, tape  350  may extend across conductive tab  315  over first end  317  extending to or towards fold  320  in embodiments. Tape  350  may be extended to cover a landing on module  310  for conductive tab  315  as will be described further below. 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 limit access locations for water ingress. 
     Battery system  300  may also include a second water resistant tape  355  extending about module  310 . Second water resistant tape  355  may be any of the materials discussed above for first water resistant tape  350 , and in some embodiments second water resistant tape  355  is the same material as first water resistant tape  350 . In other embodiments second water resistant tape  355  may be a different material than first water resistant tape  350 . For example, second water resistant tape  355  may be exposed within the device housing battery system  300 , while first water resistant tape  350  may be covered on one or more sides. Accordingly, second water resistant tape may be a thicker or more resistant material in some embodiments. 
     Second water resistant tape  355  may extend across one, two, three, or all sides of module  310 , and may at least partially contact first water resistant tape  350 . Second water resistant tape  355  may extend over or across the distal portion of electrode tab  307 , and may extend across end  308  of electrode tab  307 , and/or second end  319  of conductive tab  315 . Second water resistant tape  355  may extend beyond the ends of conductive tab  315  and electrode tab  307  and may extend at least partially across first surface  312  of module  310  and over first water resistant tape  350 . Second water resistant tape  355  may also extend at least partially along or over interior side  318  of module  310 , and may contact first water resistant tape  350 . In some embodiments, second water resistant tape  355  may also extend at least partially along or over second surface  314  of module  310 , and may contact first water resistant tape  350  over the second surface. Second water resistant tape  355  may also extend along electrode tab  307  along exterior side  316  of module  310 . Tape  355  may continue along an underside of the electrode tab  307  and continue to or towards battery cell  305 . In some embodiments, tape  355  may couple with battery cell  305 , or may extend proximate cell  305 . By including second water resistant tape over the surfaces of the module, a more complete seal may be formed across all corrodible components. 
     Battery system  300  may also include a terrace  360  extending laterally from the battery cell and supporting module  310 . Terrace  360  may be a bracket or other support structure that supports electrode tab  307  as it extends from battery cell  305 , and may be a plastic, or insulative material in embodiments. Terrace  360  may span the entire length of the batter cell  305  to fully support module  310 . Thus, along portions external from the electrode tab  307  or tabs, which may only extend partially along a length of battery cell  305 , terrace  360  may include seating tape  322  between the terrace  360  and battery module  310 . Seating tape  322  may include an increased thickness as previously discussed to accommodate the varying thickness along terrace  360  due to the inclusion of electrode tabs  307  over partial sections of the terrace, while maintaining contact with module  310  along an entire length of the module. Second water resistant tape  355  may extend across terrace  360  and may at least partially cover an underside of the structure. Accordingly, while one end of second water resistant tape  355  extends across terrace  360 , a subsequent end of second water resistant tape  355  may overlap the first end and extend across second surface  314  of module  310 , contacting seating tape  322  along the second surface  314  of module  310 . 
       FIGS. 4A-4C  show schematic views of a battery system module  400  according to embodiments of the present technology. Module  400  may include some or all of the characteristics described above for module  310 . The figures may illustrate module  400  prior to application of first water resistant tape  350  as previously discussed to show additional components described.  FIG. 4A  illustrates a view along a surface of module  400 , which may be similar to second surface  314  discussed above. Module  400  may include a circuit board  405  including a spacer  410  coupled with a surface of the circuit board. Module  400  may include one or more conductive tabs  415   a ,  415   b , which may be used to couple with electrode tabs extending from a battery cell. Tabs  415  may be the same or different materials in embodiments, depending on the material used for electrode tabs from an associated battery cell. Spacer  410  may define one or more gaps across through the structure of the spacer, and in some embodiments may at least partially define a cavity  420  through spacer  410  as previously described. The cavity  420  may provide a region into which components  425  extending from a surface of circuit board  405  may extend. During manufacture, a pottant may be flowed or coated into cavity  420  to encapsulate components  425  as previously described. 
     An additional gap may provide access for an additional component extending from circuit board  405 , as well as provide access for a locating feature to facilitate placement of the spacer  410  on circuit board  405 .  FIG. 4B  illustrates an elevation view of module  400  including how spacer  410  may by placed over feature  430 , which may extend beyond the boundaries of spacer  410 . Feature  430  may facilitate placement of spacer  410  to protect components  425  during manufacturing operations.  FIG. 4C  illustrates an additional plan view along a surface opposite the surface shown in  FIG. 4A . For example,  FIG. 4C  may illustrate a view along first surface  312  discussed above prior to application of first water resistant tape  350 . As shown, spacer  410  may not surround circuit board  405  in embodiments. Spacer  410  may be adhered to a surface of the circuit board from which components  425  extend. Spacer  410  may extend laterally beyond circuit board  405  at a distal portion  412  of spacer  410 . This may provide additional support for module  400  on an end opposite an end that may be coupled with additional circuitry or components from the circuit board  405 . 
     Circuit board  405  may include one or more landing surfaces  435  to which conductive tabs  415  may be coupled, such as welded or adhered. Landing surfaces  435  may be sized slightly larger than outer dimensions of conductive tab  415  to ensure complete coupling of the conductive tab. As discussed previously, when a tape is applied, such as first water resistant tape  350 , the tape may extend across the surface of the module past landing surfaces  435 , and may extend to a joint or fold position of conductive tab  415 . Conductive tabs  415  may include a variety of geometries providing a surface for coupling with electrode tabs of a battery cell. Although conductive tabs  415  may be rectangular, in some embodiments conductive tabs  415  may be characterized by a butterfly shape as illustrated to facilitate folding back across the surface of the module after a water resistant tape has been applied. 
     The features discussed previously may provide additional advantages in battery systems including multiple battery cells that may be included in a device. The space available for a battery within a device may determine the amount of power available, and the available run time prior to subsequent charging. Accordingly, providing additional space within a device for larger battery cells may be an enhancing feature of the device. Many conventional batteries are rectangular in shape, however, and thus extra space within a device housing having a perfectly rectangular shape may be limited. When multiple batteries are included within a housing, often those two batteries must be coupled together to provide sufficient function. Although series coupling may provide excess power, such a coupling configuration may limit control over the individual batteries. Parallel coupling may afford additional capability and monitoring, although individual control systems may be needed for each individual battery. 
     The packaging designs previously described may also afford additional benefits in multi-battery cell designs where each battery or cell includes an associated control module.  FIG. 5  illustrates a schematic plan view of one exemplary multiple battery system  500  according to embodiments of the present technology. The figure shows one possible configuration of two battery cells  505  in a configuration having an overall non-rectangular profile, although it is to be understood that many variations based on this discussion are similarly encompassed by the present technology. Battery system  500  illustrates an L-shaped two battery configuration including a power module  510  for controlling, monitoring, and coupling the two battery cells. 
     Battery system  500  may include a first battery cell  505   a  having first electrode tabs extending from a first end  506  of the battery cell  505   a , and electrically coupled with a first circuit module  512 . Battery system  500  may also include a second battery cell  505   b  positioned adjacent the first end  506  of first battery cell  505   a . Battery cell  505   b  may extend perpendicular to battery cell  505   a . Additionally, battery cell  505   b  may include second electrode tabs extending from a first end  508  of battery cell  505   b , and electrically coupled with a second circuit module  514 . The coupling of battery cells  505   a ,  505   b  with first circuit module  512  and second circuit module  514 , respectively, may be similar to the configurations previously described, such as with  FIG. 3 , for example. First circuit module  512  may extend parallel to the first end  506  of the first battery cell  505   a . Similarly, second circuit module  514  may extend parallel to the first end  508  of the second battery cell  505   b . As illustrated, a second end  509  of second battery  505   b  is positioned flush with an edge of first battery  505   a , to form an L-shaped battery system. However, it is to be understood that configurations re-positioning second battery  505   b , such as a T-shape, are similarly encompassed. 
     The first circuit module  512  and the second circuit module  514  may be coupled with one another through a power module  510 , which may provide parallel access to the two circuit modules. By coupling the two control modules or circuit modules together both electrically and communicatively, an overall system control can monitor the cells individually and as a system to provide monitoring of both cells individually, as well as to provide cell balancing capabilities, and a single power tab  522  for battery power from the two batteries at a single location. Battery system  500  may also include a tray  525 , which may be a bracket in which the system components are contained. Tray  525  may provide a structure in which the first battery cell  505   a  and the second battery cell  505   b  are seated. Tray  525  may also include a first section  526  extending along a portion of the first electrode tab included in module  512 , and a second section  528  extending along a portion of the second electrode tab included within module  514 . Bracket  525  may also include a sidewall  529  extending up a side of the battery system  500 . Sidewall  529  may extend about battery system  500  along sides of the battery cells, and may extend substantially about the sides of the battery system  500 . 
       FIG. 6  shows a schematic perspective view of a battery power module  600  according to embodiments of the present technology. Battery power module  600  may include components as described with any of the previous figures, and may illustrate a module prior to attachment with two battery cells in a configuration such as illustrated in  FIG. 5 . Some conventional technologies incorporate water ingress protection by rolling a control module in water resistant materials. However, when two or more battery control modules are incorporated on a power module, two different directions of roll would be needed, which cannot be performed when the modules are coupled together with a control module. Accordingly, the present technology allows formation of the individual circuit modules as previously discussed, and then power module  600  can be dropped in z-direction onto battery system  500  over electrode tabs prior to the final bend of the electrode tab end as shown in  FIG. 3 .  FIG. 6  illustrates a power module  600  after a first water resistant tape  605  has been applied about the module, and over a first end of conductive tabs  610 . Tabs  610  can subsequently be folded back across the surface of the circuit modules, and then power module  600  can be placed with the associated battery cells. The electrode tabs can be finally bent over the top of the modules and coupled with conductive tabs  610 . A second water resistant tape can be applied over the module as previously described to produce the final cell structure with each module. 
     Power module  600  illustrates exemplary coupling of multiple battery cell control modules or circuit modules  602 ,  604  for use in a battery system such as illustrated in  FIG. 5 . Power module  600  may include a flexible circuit material  615 , which may connect the individual circuit modules. Flexible circuit material  615  may be printed circuit board or other circuit materials that may allow electrical transmission as well as communication transmission to and from the individual circuit modules. Flexible circuit material  615  may include a first portion  617  that may extend along a first battery cell, such as battery cell  505   a . Flexible circuit material  615  may also include a second portion  619  that may extend along a second battery cell, such as battery cell  505   b . As illustrated, first portion  617  may extend in a first direction, and second portion  619  may extend in a second direction substantially normal to the first direction. The individual circuit modules  602 ,  604  may branch from the individual sections of the flexible circuit material  615 . As illustrated, for example, in some embodiments first circuit module  602  extends normal to the first portion  617  of the power module  600 . A flexible coupling  621  may electrically and communicatively couple circuit module  602  with power module  600 . Additionally, in some embodiments, second circuit module  604  extends normal to the second portion  619  of power module  600 . A flexible coupling  623  may electrically and communicatively couple circuit module  604  with power module  600 . 
     Power module  600  may include a power tab  625  extending from the power module to provide electrical and communicative coupling for a control board or system board for the device in which the battery system utilizing power module  600  may be employed. Although illustrated as extending from first portion  617  of power module  600 , power tab  625  may extend from second portion  619  in other embodiments. Additionally, power tab  625  may extend from either side of power module  600 , although in some embodiments as illustrated power tab  625  extends from a first side of power module  600  opposite a second side of power module  600  from which the first circuit module  602  and the second circuit module  604  extend. In embodiments power tab  625  may be flexibly coupled with power module  600  to provide flexibility with attachments in production. Power module  600  may include a variety of components to provide an L-shaped control module for use with an L-shaped battery system. For example, the flexible circuit material  615  may include a first rigid section as the first portion  617  of power module  600 , and a second rigid section as the second portion  619  of the power module. This may allow flush positioning adjacent the battery cells, and may allow the power module to seat within a tray, such as tray  525  discussed above. The rigid sections of the power module may sit between the tray sidewall and the batteries within the tray in some embodiments. The two rigid sections may be coupled by a flexible joint  630 , which may facilitate positioning and manufacturing tolerances of battery systems. By utilizing designs of the present technology, improved contaminant protection and water ingress prevention capabilities may be provided in a variety of battery designs and configurations including single and multiple battery cell systems. 
     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: 20171027
Publication Date: 20200211
Grant Date: 20200211
Priority Date: 20170907
Inventors: MARASCO, ANGELO V.
BOHNEY, NATHAN J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M10/425", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2010/4271", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2220/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2010/4271", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2010/4271", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M10/425", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2220/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/178", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/553", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/178", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/553", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M10/425", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 65517448