PATENT DOCUMENT

Publication Number: US-10109834-B2
Application Number: US-201715423165-A
Country: US
Kind Code: B2

Title: Modified U-tab for accommodating indeterminate battery tab locations

Abstract:
Battery assemblies, as well as methods and processes for forming same. A battery assembly can include a first tab electrically connected to a first terminal of a battery and a second tab electrically connected to a second terminal of the battery. A battery assembly can also include a first conductive path (aka first section) having a first end, and a second conductive path (aka second section) having a second end. Another end of the first conductive path can be coupled an electronic device, such as an electric circuit. Another end of the second conductive path can be coupled to the electronic device as well. A space separates the first and second ends; the space formed by removing at least one portion of a U-shaped conductive path. The first conductive path and the first battery tab are connected. The second conductive path and the second battery tab are also connected.

Claims:
The invention claimed is: 
     
       1. A method of forming a battery assembly ( 111 ), the method comprising:
 obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ); 
 obtaining a U-shaped conductive path ( 102 ); 
 determining a position of the first tab ( 104 ) and a position of the second tab ( 108 ); 
 removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ); 
 connecting the first section ( 114 ) to the first tab ( 104 ); and 
 connecting the second section ( 116 ) to the second tab ( 108 ). 
 
     
     
       2. The method of  claim 1 , wherein removing the first portion ( 112 ) of the U-shaped conductive path ( 102 ) comprises removing the first portion ( 112 ) based on the determined positions of the first tab ( 104 ) and the second tab ( 108 ). 
     
     
       3. The method of  claim 1 , further comprising removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ). 
     
     
       4. The method of  claim 3 , wherein:
 determining a position of the first tab ( 104 ) comprises determining a position of an outer side ( 122 ) of the first tab ( 104 ); 
 determining a position of the second tab ( 108 ) comprises determining a position of an outer side ( 124 ) of the second tab ( 108 ); 
 connecting the first section ( 114 ) to the first tab ( 104 ) comprises aligning a first end ( 118 ) of the first section ( 114 ) with the outer side ( 122 ) of the first tab ( 104 ); and 
 connecting the second section ( 116 ) to the second tab ( 108 ) comprises aligning a second end ( 120 ) of the second section ( 116 ) with the outer side ( 124 ) of the second tab ( 108 ). 
 
     
     
       5. The method of  claim 3 , wherein:
 determining a position of the first tab ( 104 ) comprises determining a position of an outer side ( 122 ) of the first tab ( 104 ); 
 determining a position of the second tab ( 108 ) comprises determining a position of an outer side ( 124 ) of the second tab ( 108 ); 
 connecting the first section ( 114 ) to the first tab ( 104 ) comprises setting a first end ( 118 ) of the first section ( 114 ) flush with the outer side ( 122 ) of the first tab ( 104 ); and 
 connecting the second section ( 116 ) to the second tab ( 108 ) comprises setting a second end ( 120 ) of the second section ( 116 ) flush with the outer side ( 124 ) of the second tab ( 108 ). 
 
     
     
       6. The method of  claim 3 , wherein removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) comprises removing a first portion ( 112 ) along a first line ( 127 ) that is a first distance ( 126 ) from an inner side ( 130 ) of the first tab ( 104 ), and wherein removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ) comprises removing a second portion ( 115 ) along a second line ( 129 ) that is a second distance ( 128 ) from an inner side ( 132 ) of the second tab ( 108 ). 
     
     
       7. The method of  claim 6 , wherein the first distance ( 126 ) is the same as the second distance ( 128 ). 
     
     
       8. The method of  claim 1 , wherein removing the first portion ( 112 ) of the U-shaped conductive path ( 102 ) comprises removing the first portion ( 112 ) along a line centrally located between an inner side ( 130 ) of the first tab ( 104 ) and an inner side ( 132 ) of the second tab ( 108 ). 
     
     
       9. The method of  claim 1 , wherein removing the first portion ( 112 ) of the U-shaped conductive path ( 102 ) comprises removing the first portion ( 112 ) along a line centrally located between a centerline ( 138 ) of the first tab ( 104 ), and a centerline of the second tab ( 108 ). 
     
     
       10. The method of  claim 1 , wherein removing the first portion ( 112 ) of the U-shaped conductive path ( 102 ) comprises removing the first portion ( 112 ) along a line formed by an inner side ( 130 ) of the first tab ( 104 ). 
     
     
       11. The method of  claim 10 , further comprising removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ) along a line formed by an inner side ( 132 ) of the second tab ( 108 ). 
     
     
       12. A battery assembly ( 111 ) comprising:
 a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of a battery ( 100 ) and a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ), the first tab ( 104 ) and the second tab ( 108 ) each having an inner side ( 130 ,  132 ) and an outer side ( 122 ,  124 ); and 
 a first conductive path ( 114 ) having a first end ( 118 ) and a second conductive path ( 116 ) having a second end ( 120 ), the first and second ends ( 118 ,  120 ) separated by space ( 113 ) formed by removing at least one portion ( 112 ) of a U-shaped conductive path ( 102 ), 
 wherein the first conductive path ( 114 ) is connected to the first tab ( 104 ), and wherein the second conductive path ( 116 ) is connected to the second tab ( 108 ). 
 
     
     
       13. The battery assembly ( 111 ) of  claim 12 , wherein the first end ( 118 ) of the first conductive path ( 114 ) is aligned with the outer side ( 122 ) of the first tab ( 104 ), and wherein the second end ( 120 ) of the second conductive path ( 116 ) is aligned with the outer side ( 124 ) of the second tab ( 108 ). 
     
     
       14. The battery assembly ( 111 ) of  claim 12 , wherein the first end ( 118 ) of the first conductive path ( 114 ) is flush with the outer side ( 122 ) of the first tab ( 104 ), and wherein the second end ( 120 ) of the second conductive path ( 116 ) is flush with the outer side ( 124 ) of the second tab ( 108 ). 
     
     
       15. The battery assembly ( 111 ) of  claim 12 , wherein the first end ( 118 ) is a first distance ( 126 ) from the inner side ( 130 ) of the first tab ( 104 ), and wherein the second end ( 120 ) is a second distance ( 128 ) from the inner side ( 132 ) of the second tab ( 108 ). 
     
     
       16. The battery assembly ( 111 ) of  claim 15 , wherein the first distance ( 126 ) is the same as the second distance ( 128 ). 
     
     
       17. The battery assembly ( 111 ) of  claim 12 , wherein the space ( 113 ) is centrally located between the inner side ( 130 ) of the first tab ( 104 ) and the inner side ( 132 ) of the second tab ( 108 ). 
     
     
       18. The battery assembly ( 111 ) of  claim 12 , wherein the space ( 113 ) overlaps a line midway between the inner side ( 130 ) of the first tab ( 104 ) and the inner side ( 132 ) of the second tab ( 108 ). 
     
     
       19. The battery assembly ( 111 ) of  claim 12 , wherein the space ( 113 ) overlaps a line midway between a centerline ( 138 ) of the first tab ( 104 ) and a centerline of the second tab ( 108 ). 
     
     
       20. The battery assembly ( 111 ) of  claim 12 , wherein the first end ( 118 ) is collinear with the inner side ( 130 ) of the first tab ( 104 ). 
     
     
       21. The battery assembly ( 111 ) of  claim 20 , wherein the second end ( 120 ) is collinear with the inner side ( 132 ) of the second tab ( 108 ). 
     
     
       22. A battery assembly ( 111 ) formed by:
 determining a position of a first tab ( 104 ) connected to a first terminal ( 106 ) of a battery ( 100 ); 
 determining a position of a second tab ( 108 ) connected to a second terminal ( 110 ) of the battery ( 100 ); 
 partitioning a U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ), wherein partitioning the U-shaped conductive path ( 102 ) comprises removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ); 
 connecting the first section ( 114 ) to the first tab ( 104 ); and 
 connecting the second section ( 116 ) to the second tab ( 108 ). 
 
     
     
       23. The battery assembly ( 111 ) of  claim 22 , wherein removing the first portion ( 112 ) of the U-shaped conductive path ( 102 ) comprises removing the first portion ( 112 ) based on the determined positions of the first tab ( 104 ) and the second tab ( 108 ). 
     
     
       24. The battery assembly ( 111 ) of  claim 23 , wherein partitioning the U-shaped conductive path ( 102 ) further comprises removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ).

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 62/399,154, filed on Sep. 23, 2016, which is fully incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     This disclosure relates generally to connectors for connecting electronic components to batteries, and, in particular, to connectors that can accommodate variances in placement of connective tabs of batteries due to, e.g., manufacturing tolerances. 
     BACKGROUND 
     Some batteries employed in portable electronic devices employ so-called battery tabs connected to the terminals (i.e., the positive and negative terminals) of the battery. These tabs facilitate connection of the battery to the electronic components of the device. The connective tabs of a battery are spatially separated from one another to prevent short circuiting of the battery. Sometimes, the electronic devices to which the battery is to be connected, such as a printed circuit board (PCB) assembly, will employ connectors that are in some respects similar to the battery tabs. Such connectors may be similarly separated to prevent short circuiting. Due to manufacturing tolerances, the exact location of a battery&#39;s connective tabs may vary from battery to battery. In some cases, device-side connectors are designed so that the spacing between connectors (e.g., between a positive and negative connector) will accommodate battery manufacturing tolerances, to ensure proper connection between device-side and battery-side connectors. This can cause the device-side connectors (and the overall battery-to-device connection) to have larger than necessary footprints, which can take up valuable space in a portable electronic device. 
     SUMMARY 
     Disclosed herein are various connector embodiments to connect electronic components, such as printed circuit boards, to battery tabs, as well as methods for forming such connections. The connectors can be fashioned from a single U-shaped piece of conductive material by creating a gap in the U-shaped piece of conductive material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Implementations of the present application will now be described, by way of example only, with reference to the attached figures, wherein: 
         FIG. 1  illustrates components that can be utilized to form a battery assembly; 
         FIG. 2  illustrates a battery assembly according to some embodiments; 
         FIG. 3  illustrates components that can form a battery assembly; 
         FIG. 4  illustrates a battery assembly according to some embodiments; 
         FIG. 5  illustrates a battery assembly according to some embodiments; 
         FIG. 6  illustrates a battery assembly according to some embodiments; 
         FIG. 7  illustrates a battery assembly according to some embodiments; 
         FIG. 8  illustrates a battery assembly according to some embodiments; 
         FIG. 9  illustrates a battery assembly according to some embodiments; 
         FIG. 10  illustrates a battery assembly according to some embodiments; 
         FIG. 11  illustrates a battery assembly according to some embodiments; 
         FIG. 12  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 13  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 14  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 15  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 16  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 17  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 18  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 19  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 20  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 21  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 22  illustrates a method of forming a battery assembly according to some embodiments; 
         FIG. 23  illustrates a process by which a battery assembly can be formed according to some embodiments; 
         FIG. 24  illustrates a process by which a battery assembly can be formed according to some embodiments; and 
         FIG. 25  illustrates a process by which a battery assembly can be formed according to some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments of the disclosed concepts are described below with reference to the figures. The descriptions are examples and not limitation. Throughout this disclosure, the phrases “first conductive path” and “second conductive path” are synonymous with the phrases “first section of a U-shaped conductive path” (or simply “first section”) and “second section of a U-shaped conductive path” (or simply “second section”), respectively. 
       FIG. 1  illustrates components that can be utilized to form a battery assembly. A U-shaped conductive path  102  is shown above a battery  100 . The U-shaped conductive path  102  is coupled to electronic device  101 . The electronic device can be a circuit, circuit component, printed circuit board, or the like. The battery  100  has a first tab  104  electrically connected to its first terminal  106 . The battery  100  also has a second tab  108  electrically connected to its second terminal  110 . 
     In some embodiments, the position of the first tab  104  and the position of the second tab  108 —which can vary from battery to battery due to manufacturing tolerances—are determined. A machine vision system (not shown) or other type of industrial locating and positioning system can be used to determine positions of the tabs  104 ,  108 . With the positions of the tabs  104 ,  108  determined, the U-shaped conductive path  102  can be partitioned into a first section and a second section. Partitioning may be done by removing a first portion  112 . 
     An ablating tool or some other cutting or removal tool can be used to separate the U-shaped conductive path  102  into sections, as illustrated by  114 ,  116  of  FIG. 2 . The determination as to where to remove the first portion  112  can be based, at least in part, on the locations of the battery tabs  104 ,  108 . The removed portion  112  can be made wide enough to separate the sections  114 ,  116  ( FIG. 2 ) by a minimum safe distance. The space between the sections can, for example, be made wide enough to prevent short circuiting and/or electromagnetic coupling between the sections  114 ,  116 , the battery tabs  104 ,  108 , and/or battery terminals  106 ,  110 , respectively. With the U-shaped conductive path  102  partitioned, the first section  114  can be connected to the first tab  104 , and the second section  116  can be connected to the second tab  108 , so as to form a battery assembly as illustrated in  FIG. 2 . The sections of the U-shaped conductive path  102  can be connected to the tabs  104 ,  108  by welding, soldering, or other process that establishes an electrical connection therebetween. 
     With continued reference to  FIG. 2 , an exemplary battery assembly  111  is illustrated. Battery assembly  111  includes a first tab  104 , which is electrically connected to a first terminal  106  of a battery  100 , and a second tab  108 , which is electrically connected to a second terminal  110  of the battery  100 . The first tab  104  has an outer side  122  and an inner side  130 . The second tab  108  has an outer side  124  and an inner side  132 . The embodiment also includes a first conductive path  114  having a first end  118  and a second conductive path  116  having a second end  120 . The first end  118  is separated from the second end  120  by a space  113 . The space  113  may be formed by removing a portion ( 112 ) of a U-shaped conductive path ( 102 ). (See  FIG. 1 .) In the embodiment of  FIG. 2 , the first conductive path  114  is connected, electrically and mechanically, to the first tab  104 , and the second conductive path  116  is connected, electrically and mechanically, to the second tab  108 . 
     Battery assembly  111  illustrated in  FIG. 2  can be formed by determining a position of a first tab  104  connected to a first terminal  106  of a battery  100 , determining a position of a second tab  108  connected to a second terminal  110  of the battery  100 , and then partitioning a U-shaped conductive path ( 102 ) into a first section  114  and a second section ( 116 ). The U-shaped conductive path ( 102 ) can be partitioned by removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ). Formation of the battery assembly  111  can be completed by electrically and mechanically connecting the first section  114  to the first tab  104 , and connecting the second section  116  to the second tab  108 . 
       FIG. 3  illustrates that in addition to the first portion  112 , a second portion  115  can be removed from the U-shaped conductive path  102 , which also results in the removal of the section of U-shaped conductive path  102  disposed between the first portion  112  and the second portion  115 . U-shaped conductive path  102  is shown above a battery  100 . The battery  100  has a first tab  104  electrically connected to its first terminal  106 . The battery  100  also has a second tab  108  electrically connected to its second terminal  110 . According to one method of forming a battery assembly ( 111 ), the position of the first tab  104  and the position of the second tab  108  are determined. A vision system can be used to determine positions of the tabs  104 ,  108 . Once the positions of the tabs  104 ,  108  are determined, the U-shaped conductive path  102  can be partitioned into a first section (e.g.,  114  in  FIG. 4 ) and a second section (e.g.,  116  in  FIG. 4 ). In some embodiments, partitioning is done by removing a first portion  112 . Optionally, after the first portion  112  is removed, a second portion  115  can also be removed, which will also remove the section of U-shaped conductive path  102  located between first portion  112  and second portion  115 . As indicated previously, an ablating tool or some other removal tool known in the art can be used to remove the first portion  112  and the second portion  115 . The determination as to where to remove the first portion  112  and the second portion  115  can be based, at least in part, on the locations of the tabs  104 ,  108  as determined by a machine vision or other industrial location system. Removing two portions from the U-shaped conductive path  102  will, in most instances, create a gap between the sections  114 ,  116  that is larger than if only one portion were removed because the section of the U-shaped conductive path  102  between the two portions  112  and  115  is also removed. As was discussed with regard to  FIG. 1 , once the two portions  112 ,  114  are removed from the U-shaped conductive path  102 , the first section ( 114 ) can be connected to the first tab  104 , and the second section ( 116 ) can be connected to the second tab  108 . Again, the sections of the U-shaped conductive path  102  can be connected to the tabs  104 ,  108  by welding, soldering, or other process that establishes an electrical connection therebetween. 
       FIG. 4  illustrates battery assembly  111  in accordance with some embodiments, in which battery assembly  111  includes a first tab  104 , which is electrically connected to a first terminal  106  of a battery  100 , and a second tab  108 , which is electrically connected to a second terminal  110  of the battery  100 . The first tab  104  has an outer side  122  and an inner side  130 . Likewise, the second tab  108  has an outer side  124  and an inner side  132 . The embodiment also includes a first conductive path  114  having a first end  118  and a second conductive path  116  having a second end  120 . The first end  118  is separated from the second end  120  by a space  113 . The space  113  can be formed by removing a first portion ( 112 ) and then a second portion ( 115 ) from a U-shaped conductive path ( 102 ). As before, the first conductive path  114  is connected to the first tab  104 , and the second conductive path  116  is connected to the second tab  108 . The space  113  separating conductive path  114  from conductive path  116  is larger than that of  FIG. 2 . In the embodiment of  FIG. 4 , the first end  118  of the first conductive path  114  is aligned with an outer side  122  of the first tab  104 , and the second end  120  of the second conductive path  116  is aligned with the outer side  124  of the second tab  108 . The embodiment of the battery assembly  111  illustrated in  FIG. 4  can be formed by first determining a position of an outer side  122  of the first tab  104 , then determining a position of an outer side  124  of the second tab  108 . The first end  118  of the first section  114  can then be aligned with the outer side  122  of the first tab  104 , and the second end  120  of the second section  116  can be aligned with the outer side  124  of the second tab  108  as shown. The battery assembly  111  is completed by connecting the first section  114  to the first tab  104  and connecting the second section  116  to the second tab  108 . 
       FIG. 5  illustrates another battery assembly  111  in accordance with some embodiments. Battery assembly  111  illustrated in  FIG. 5  is similar to that illustrated in  FIG. 4 , except that the ends  118 ,  120  of the conducive paths are flush with the outer sides  122 ,  124  of the battery tabs  104 ,  108 . Battery assembly  111  includes a first tab  104 , which is electrically connected to a first terminal  106  of a battery  100 , and a second tab  108 , which is electrically connected to a second terminal  110  of the battery  100 . The first tab  104  has an outer side  122  and an inner side  130 . Likewise, the second tab  108  has an outer side  124  and an inner side  132 . Battery assembly  111  also includes a first conductive path  114  having a first end  118  and a second conductive path  116  having a second end  120 . The first end  118  is a distance from the second end  120 , separated by a space  113 . The space  113  can be formed by removing a first portion ( 112 ) and then a second portion ( 115 ) from a U-shaped conductive path ( 102 ). As described above, the first conductive path  114  is connected to the first tab  104 , and the second conductive path  116  is connected to the second tab  108 . The space  113  separating conductive path  114  from conductive path  116  is larger than that of  FIG. 2 . As illustrated in  FIG. 5 , the first end  118  of the first conductive path  114  is flush with the outer side  122  of the first tab  104 , and the second end  120  of the second conductive path  116  is flush with an outer side  124  of the second tab  108 , that is, the both ends  118 ,  120 , are in full contact with the outer sides  122 ,  124  of the first and second tabs  104 ,  108 , respectively. 
     The battery assembly  111  illustrated in  FIG. 5  can be formed by first determining a position of an outer side  122  of the first tab  104 , then determining a position of an outer side  124  of the second tab  108 . The first end  118  of the first section  114  can then be set flush with the outer side  122  of the first tab  104 , and the second end  120  of the second section  116  can be set flush with the outer side  124  of the second tab  108  as shown. The battery assembly  111  is completed by connecting the first section  114  to the first tab  104  and connecting the second section  116  to the second tab  108 . 
       FIG. 6  illustrates another battery assembly  111  in accordance with some embodiments. Battery assembly  111  includes a first tab  104 , which is electrically connected to a first terminal  106  of a battery  100 , and a second tab  108 , which is electrically connected to a second terminal  110  of the battery  100 . The first tab  104  has an outer side  122  and an inner side  130 . Likewise, the second tab  108  has an outer side  124  and an inner side  132 . Battery assembly  111  also includes a first conductive path  114  having a first end  118  and a second conductive path  116  having a second end  120 . The first end  118  is separated from the second end  120  by a space  113 . The space  113  can have been formed by removing first and second portions ( 112 ,  115 ) from a U-shaped conductive path ( 102 ). The first conductive path  114  is connected to the first tab  104 , and the second conductive path  116  is connected to the second tab  108 . The first end  118  of the first conductive path  114  is a first distance  126  from the inner side  130  of the first tab  104 , and the second end  120  is a second distance  128  from an inner side  132  of the second tab  108 . 
     Battery assembly  111  illustrated in  FIG. 6  can be formed by determining a position of a first tab  104  connected to a first terminal  106  of a battery  100  and a position of a second tab  108  connected to a second terminal  110  of the battery  100  using a machine vision or other industrial sensing and positioning system. A first portion ( 112 ) of the U-shaped tab can be removed along a first line  127  that is a first distance  126  from an inner side  130  of the first tab  104 , forming a first section  114  and a second section  116 . (Alternatively, the location of the portion to be removed can be located with respect to an outer side or a centerline of the battery tab.) A second portion ( 115 ) of the U-shaped tab can be removed along a second line  129  that is a second distance  128  from an inner side  132  of the second tab  108 , thereby making the second section  116  smaller than it was and increasing the space  113  between the end  118  of the first section  114  and the end  120  of the second section  116 . (Alternatively, the location of the portion to be removed can be located with respect to an outer side or a centerline of the battery tab.) Thereafter, the first section  114  can be connected to the first tab  104 , and the second section  116  can be connected to the second tab  108 . 
       FIG. 7  illustrates another battery assembly  111  in accordance with some embodiments. The battery assembly  111  of  FIG. 7  is similar to that of  FIG. 6 , except the distance  126  from the first end  118  of the first section  114  to the inner side  130  of the first tab  104  is the same as the distance  128  from the second end  120  of the second section  116  from the inner side  132  of the second tab  108 . 
     Battery assembly  111  as illustrated in  FIG. 7  can be constructed by acquiring a battery  100  that has a first tab  104  that is electrically connected to a first terminal  106  of the battery  100 , and a second tab  108  that is electrically connected to a second terminal  110 . A U-shaped conductive path ( 102 ) is then obtained. The positions of the first and second tabs  104 ,  108  are determined; the positions of the inner sides ( 130 ,  132 ) of the tabs ( 104 , 108 ) can be determined. A first portion ( 112 ) is removed along a line that is a distance  126  from the inner side  130  of tab  104 , and a second portion ( 115 ) is removed along a line that is the same distance  128  from the inner side  132  of the second battery tab  108 . (Alternatively, the location of the portion to be removed can be located with respect to an outer side or a centerline of the battery tab.) 
       FIG. 8  illustrates another battery assembly  111  in accordance with some embodiments, which is similar to some of the embodiments described above. Note, though, that space  113  is smaller than in  FIG. 7 . The space  113  is formed by removing only a portion ( 112 ) at about the halfway point between the tabs  104 ,  108 . The first conductive path  114  is coupled to the first terminal  106  via the first tab  104  and the second conductive path  116  is coupled to the second terminal  110  via the second tab  108 . The first and second conductive paths  114 ,  116  are separated by space  113  formed by removing a portion ( 112 ) of a U-shaped conductive path ( 102 ) along a line centrally located between the inner sides  130 ,  132  of the battery tabs  104 ,  108 . 
       FIG. 9  illustrates another battery assembly  111  similar to that of  FIG. 8 ; however, space  113  is larger and is not as centralized between the tabs  104 ,  108 . The space  113  between the sections  114  and  116  overlaps a line  134  that is midway between an inner side  130  of the first tab  104  and an inner side  132  of the second tab  108 , the space  113  having been created by removing at least one portion ( 112 ) of a U-shaped conductive path ( 102 ) along said line  134 . Selection of a first cutting line  134  could involve locating the inner sides  130 ,  132  of the tabs  104 ,  108 , dividing the distance between the two  130 ,  132  in half. After a first portion ( 112 ) is removed, a second portion ( 115 ) can be removed at some distance line  134 , thereby enlarging space  113 . 
       FIG. 10  illustrates a battery assembly  111  similar to that of  FIG. 9 ; however, centerlines  138 ,  140  of tabs  104 ,  108  are used as reference during formation of assembly  111 . Also, the space  113  between the conductive paths  114 ,  116  overlaps a line  136 , which is midway between a centerline  138  of the first tab  104 , and a centerline  140  of the second tab  108 , the space  113  having been created by removing at least one portion ( 112 ) of a U-shaped conductive path ( 102 ) along said line  136 . Selection of the cutting line  136  could involve locating the centerlines  138 ,  140  of the tabs  104 ,  108  and dividing the distance between the two  138 ,  140  in half. 
       FIG. 11  illustrates a battery assembly  111  in accordance with some embodiments and in which the first and second tabs  104 ,  108  are connected to first and second terminals  106 ,  110  of a battery  100  as described above with reference to  FIGS. 2-10 . The first conductive path  114  is connected to the first tab  104 , and the second conductive path  116  is connected to the second tab  108 . However, the first end  118  of the first conductive path  114  is aligned with the inner edge  130  of the first tab  104 , and the second end  120  of the second conductive path  116  is aligned with the inner edge  132  of the second tab  108 . The first end  118  of the first conductive path  114  can be aligned with the inner side  130  of the first tab  104  by removing a first portion ( 112 ) of a U-shaped conductive path ( 102 ) along a line that overlaps the inner side  130  of the first tab  104 . The second end  120  of the second conductive path  116  can be aligned with the inner side  132  of the second tab  108  by removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ) along a line that overlaps the inner side  132  of the second tab  108 . As an alternative, the ends of the first and second portions could be aligned with the centerlines of the corresponding battery tabs, or could be aligned merely to provide any desired minimal degree of overlap with the battery tabs. 
       FIG. 12  illustrates a method  200  of forming a battery assembly ( 111 ) in accordance with some embodiments. Method  200  can begin (step  201 ) with obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). The method  200  can also include step  202 , which includes obtaining a U-shaped conductive path ( 102 ). In step  203 , the positions of the first and second tabs ( 104 ,  108 ) can be determined  203 . As described above, this may be done using a machine vision or other industrial sensing and positioning system. Additionally, the positions of tabs may be determined by reference to their edges and/or centerlines, or any suitable combination thereof. Step  204  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). In step  205 , the first section ( 114 ) can be connected to the first tab ( 104 ), and in step  206  the second section ( 116 ) can be connected to the second tab ( 108 ). 
       FIG. 13  illustrates another method  210  of forming a battery assembly ( 111 ), which differs from that illustrated in  FIG. 12  in that removing a first portion ( 112 ) is based on the determined positions of the tabs ( 104 ,  108 ). Step  211  of method  210  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). The method  210  can further include step  212 , which includes obtaining a U-shaped conductive path ( 102 ). At step  213 , the positions of the first and second tabs ( 104 , 108 ) can be determined  203 . Step  214  includes removing, based on the determined positions, a first portion ( 112 ) of the U-shaped conductive path ( 102 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  215  can include connecting the first section ( 114 ) to the first tab ( 104 ), and step  216  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 14  illustrates another method  220  of forming a battery assembly ( 111 ), which can include step  221 , obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  222  can include obtaining a U-shaped conductive path ( 102 ). In step  223 , the positions of the first and second tabs ( 104 ,  108 ) can be determined  203 , which may be done as described above. Step  224  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). In step  225 , a second portion ( 115 ) of the U-shaped conductive path ( 102 ) can be removed. In step  226 , the first section ( 114 ) is connected to the first tab ( 104 ), and in step  227 , the second section ( 116 ) can be connected to the second tab ( 108 ). 
       FIG. 15  illustrates another method  240  of forming a battery assembly ( 111 ). Step  241  of the method  240  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  242  can also include obtaining a U-shaped conductive path ( 102 ). At step  243 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. As noted above, these positions may be determined using a machine vision or other industrial locating and positioning system and may be based on the edges of the tabs, the centerlines of the tabs, or various combinations thereof. In step  244  a first portion ( 112 ) of the U-shaped conductive path ( 102 ) can be removed to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). In step  245  a second portion ( 115 ) of the U-shaped conductive path ( 102 ) can be removed. At step  246 , the end of the first section ( 114 ) can be aligned with the outer side ( 122 ) of the first tab ( 104 ). At step  247 , the end of the second section ( 116 ) can be aligned with the outer side ( 124 ) of the second tab ( 108 ). Step  248  can include connecting the first section ( 114 ) to the first tab ( 104 ) and connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 16  illustrates another method  250  of forming a battery assembly ( 111 ). Step  251  of the method  250  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  252  can include obtaining a U-shaped conductive path ( 102 ). At step  253 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. Step  254  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). In step  255 , a second portion ( 115 ) of the U-shaped conductive path ( 102 ) can be removed. Step  256  can include setting the first end ( 118 ) of the first section ( 114 ) flush with the first tab ( 104 ) and connecting the first section ( 114 ) to the first tab ( 104 ). At step  257 , the second end ( 120 ) of the second section ( 116 ) can be set flush with the second tab ( 108 ) and the second section ( 116 ) can be connected to the second tab ( 108 ). 
       FIG. 17  illustrates another method  260  of forming a battery assembly ( 111 ). Step  261  of the method  260  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  262  can include obtaining a U-shaped conductive path ( 102 ). In step  263 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. Step  264  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) along a line that is a first distance ( 126 ) from the inner side ( 130 ) of the first tab ( 104 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  265  can include removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ) along a line that is a second distance ( 128 ) from the inner side ( 132 ) of the second tab ( 108 ). Step  266  can include connecting the first section ( 114 ) to the first tab ( 104 ). Step  267  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 18  illustrates another method  270  of forming a battery assembly ( 111 ). Step  271  of the method  270  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  272  can include obtaining a U-shaped conductive path ( 102 ). In step  273 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. In step  274  a first portion ( 112 ) of the U-shaped conductive path ( 102 ) is removed along a line that is a first distance ( 126 ) from the inner side ( 130 ) of the first tab ( 104 ) to partition the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  275  can include removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ) along a line that is the same distance from the inner side ( 132 ) of the second tab ( 108 ) as the first line ( 127 ) is from the inner side ( 130 ) of the first tab ( 104 ). Step  276  can include connecting the first section ( 114 ) to the first tab ( 104 ). Step  277  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 19  illustrates another method  280  of forming a battery assembly ( 111 ). Step  281  of the method  280  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  282  can include obtaining a U-shaped conductive path ( 102 ). In step  283 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. Step  284  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) along a line centrally located between an inner side ( 130 ) of a first tab ( 104 ) and an inner side ( 132 ) of a second tab ( 108 ), thereby partitioning the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  285  can include connecting the first section ( 114 ) to the first tab ( 104 ). Step  286  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 20  illustrates another method  290  of forming a battery assembly ( 111 ). Step  291  of the method  290  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  292  can include obtaining a U-shaped conductive path ( 102 ). In step  293 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. Determining the positions of the first and second tabs ( 104 ,  108 ) can include determining the locations of centerlines of the tabs ( 104 ,  108 ). Step  294  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) along a line that is centrally located between a centerline of a first tab ( 104 ) and a centerline of a second tab ( 108 ), thereby partitioning the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  295  can includes connecting the first section ( 114 ) to the first tab ( 104 ), and step  296  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 21  illustrates another method  300  of forming a battery assembly ( 111 ). Step  301  of the method  300  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  302  can include obtaining a U-shaped conductive path ( 102 ). At step  303 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. In step  304  a first portion ( 112 ) of the U-shaped conductive path ( 102 ) is removed along a line formed by an inner side ( 130 ) of the first tab ( 104 ) (or along a line formed by an inner side ( 132 ) of the second tab ( 108 )), thereby partitioning the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  305  can include connecting the first section ( 114 ) to the first tab ( 104 ), and step  306  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 22  illustrates another method  310  of forming a battery assembly ( 111 ). Step  311  of the method  310  can include obtaining a battery ( 100 ) having a first tab ( 104 ) electrically connected to a first terminal ( 106 ) of the battery ( 100 ) and having a second tab ( 108 ) electrically connected to a second terminal ( 110 ) of the battery ( 100 ). Step  312  can include obtaining a U-shaped conductive path ( 102 ). At step  313 , the positions of the first and second tabs ( 104 ,  108 ) can be determined. Step  314  can include removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) along a line formed by an inner side ( 130 ) of the first tab ( 104 ) (or along a line formed by an inner side ( 132 ) of the second tab ( 108 )), thereby partitioning the U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ). Step  315  can include removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ) along a line formed by an inner side ( 132 ) of the second tab ( 108 ) (or along a line formed by an inner side ( 130 ) of the first tab ( 104 )). Step  316  can include connecting the first section ( 114 ) to the first tab ( 104 ). Step  317  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 23  illustrates a process for constructing a battery assembly. The process  320  can include determining  321  a position of a first tab ( 104 ) connected to a first terminal ( 106 ) of a battery ( 100 ) and determining  322  a position of a second tab ( 108 ) connected to a second terminal ( 110 ) of the battery ( 100 ). The process can also include partitioning a U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ) by removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ). Step  324  can include connecting the first section ( 114 ) to the first tab ( 104 ), and step  325  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 24  illustrates another process for constructing a battery assembly. The process  330  can include determining  331  a position of a first tab ( 104 ) connected to a first terminal ( 106 ) of a battery ( 100 ) and determining  332  a position of a second tab ( 108 ) connected to a second terminal ( 110 ) of the battery ( 100 ). Step  333  can include partitioning, based on the positions of the first and second tabs ( 104 ,  108 ), a U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ) by removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ). Step  334  can include connecting the first section ( 114 ) to the first tab ( 104 ), and step  335  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
       FIG. 25  illustrates another process for constructing a battery assembly. The process  340  can include determining  341  a position of a first tab ( 104 ) connected to a first terminal ( 106 ) of a battery ( 100 ), and determining  342  a position of a second tab ( 108 ) connected to a second terminal ( 110 ) of the battery ( 100 ). Step  343  can include partitioning, based on the positions of the first and second tabs ( 104 ,  108 ), a U-shaped conductive path ( 102 ) into a first section ( 114 ) and a second section ( 116 ) by removing a first portion ( 112 ) of the U-shaped conductive path ( 102 ) and removing a second portion ( 115 ) of the U-shaped conductive path ( 102 ). Step  344  can include connecting the first section ( 114 ) to the first tab ( 104 ), and step  345  can include connecting the second section ( 116 ) to the second tab ( 108 ). 
     The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only. Changes may be made in the detail, including in matters of shape, size and arrangement of the parts within the principles of the present disclosure up to, and including, the full extent established by the broad general meaning of the terms used in the claims.

Metadata:
Filing Date: 20170202
Publication Date: 20181023
Grant Date: 20181023
Priority Date: 20160923
Inventors: WERLEY, CHARLES W.
BOOVARAGAVAN, VIJAYASEKARAN
MARASCO, ANGELO V.
TON, THAI T.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M50/528", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/55", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2220/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/55", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/528", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2220/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2220/30", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 61688061