PATENT DOCUMENT

Publication Number: US-9812680-B2
Application Number: US-201213599377-A
Country: US
Kind Code: B2

Title: Low Z-fold battery seal

Abstract:
A portable electronic device comprises an electromechanical module having an actuator for positioning a mechanical element between first and second positions, and a controller coupled to the electromechanical module. The controller is configured to detect a mechanical event coupling to the electromechanical module, select an actuation signal to position the mechanical element in a safe position between the first and second positions, and transmit the selected signal, such that the mechanical element is positioned in the safe position during the event.

Claims:
The invention claimed is: 
     
       1. A battery assembly comprising:
 a battery element for storing electrical energy; 
 a battery case comprising first and second casing portions formed about the battery element, the first and second casing portions defining first and second major surfaces of the battery case; 
 a seal structure for sealing the battery case about the battery element, the seal structure comprising a bond between the first and second casing portions, the bond extending along a side of the battery case, the side extending between the first and second major surfaces; 
 a fold in the seal structure, wherein the fold positions the seal structure against the side of the battery case in a substantially perpendicular orientation with respect to the first and second major surfaces; 
 a protective wrap positioned about the battery case; 
 a first adhesive detachably coupling the protective wrap to the battery case and having a first bonding strength; and 
 a second adhesive detachably coupling a first portion of the protective wrap to a second portion of the protective wrap and having a second bonding strength greater than the first bonding strength. 
 
     
     
       2. The battery assembly of  claim 1 , further comprising a third adhesive provided along the side of the battery case, wherein the third adhesive retains the seal structure against the side of the battery case in the substantially perpendicular orientation with respect to the first and second major surfaces. 
     
     
       3. The battery assembly of  claim 1  further comprising an insulating layer formed over an exposed end of the seal structure. 
     
     
       4. The battery assembly of  claim 1 , wherein the protective wrap provides a compressive coupling to retain the seal structure in the substantially perpendicular orientation along the side of the battery case. 
     
     
       5. The battery assembly of  claim 1 , further comprising a color-coded tab configured to detach the protective wrap by overcoming a bonding force of the first and second adhesives. 
     
     
       6. The battery assembly of  claim 4 , wherein the protective wrap comprises a cutout configured to space an edge of the protective wrap from a connector of the battery assembly. 
     
     
       7. The battery assembly of  claim 4 , wherein the protective wrap comprises a transparent portion to view an indicia on the battery case. 
     
     
       8. The battery assembly of  claim 1 , further comprising a second seal structure formed by a second bond between the first and second casing portions, the second bond extending along an opposite side of the battery case, wherein a second fold positions the second seal structure in the substantially perpendicular orientation along the opposite side. 
     
     
       9. A portable electronic device comprising the battery assembly of  claim 1 .

Description:
BACKGROUND 
     This disclosure relates generally to portable electronic devices, and specifically to battery powered mobile devices. In particular, the disclosure relates to sealing structures for the battery assembly, as related to overall battery size, energy density and form factor. 
     Batteries come in a range of different architectures and forms, including traditional rod-and-tube (dry cell) and flat plate (flooded cell) designs, and more advanced “jelly roll” configurations in which the anode and cathode layers are laid down on opposite sides of a flat sheet or flexible substrate, coated with a liquid or gel electrolyte, and rolled up for insertion into a cylindrical battery case, which is then sealed at either end. In flat battery designs, the anode and cathode structure may be folded inside a low-profile casing or pouch, which is sealed along one or more opposite sides. Where the seal or “tail” structure is folded over the top of the battery, as in typical existing designs, it may increase battery height or thickness. Alternatively, where battery thickness is constrained, a tail structure folded over the top of the battery reduces the available volume for energy storage. 
     Battery configurations for portable electronics and mobile devices require a range of design tradeoffs, including size, weight, power consumption, manufacturability, durability and thermal loading. Each of these factors impacts overall storage capacity and energy density, as defined by the amount of useful energy that can be delivered per unit volume or mass. The battery form factor (or package shape) is also an important design consideration, particularly for compact portable and mobile devices where space is at a premium. At the same time, effective sealing and insulating mechanism are also required, in order to provide high energy density and service life with improved durability leakage prevention. 
     SUMMARY 
     Exemplary embodiments of the present disclosure include. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a battery assembly with reduced z-fold seal and protective wrap. 
         FIG. 2  is a cross-sectional view of the battery assembly. 
         FIG. 3  is a perspective view of the battery assembly, with an alternate form factor. 
         FIG. 4A  is a top view of the battery assembly, in a width-wise wrapping configuration. 
         FIG. 4B  is a bottom view of the width-wise wrapping configuration. 
         FIG. 5  is a perspective view of the battery assembly positioned in a storage tray or shipping unit. 
         FIG. 6  is a plan view of a protective wrap for the battery assembly. 
         FIG. 7  is a block diagram of a method for retaining a low z-fold seal against the side of a battery assembly for storage and installation. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a perspective view of battery assembly  10  with casing  12  and protective wrap or film  14 . Low z-fold seal structures  16  seal battery casing  12  to prevent leakage of electrolytes and other materials from the inside of battery assembly  10 , to inhibit moisture intrusion, and to reduce oxidation and corrosion of the anode and cathode surfaces. 
     In the particular configuration of  FIG. 1 , battery assembly  10  has a substantially oblong or rectangular geometry or form factor, with width W defined between opposite sides  18 A and  18 B, and length L defined between opposite sides or ends  19 A and  19 B. Battery assembly  10  may also have a flat or substantially planar profile, with first and second major surfaces  20 A and  20 B separated by thickness T. 
     Length L, width W and thickness T define the form factor of battery assembly  10 , as installed in an electronic device. Length L and width W are measured along first or second major surface  20 A or  20 B, in the direction of (horizontal) axes x and y, excluding the thickness of protective wrapper or film  14 . Similarly, height or thickness T is measured between major surfaces  20 A and  20 B, along (vertical) axis z, also excluding protective wrapper  14 . 
     In low-profile or flat configurations of battery assembly  10 , thickness T is generally less than length L or width W, such that major surfaces  20 A and  20 B have substantially greater surface area than side and end surfaces  18 A,  18 B,  19 A and  19 B. Note, however, that the orientation of coordinate axes x, y, and z is arbitrary, and length L and width W may be interchanged, such that L≧W or W≧L. The designation of sides  18 A,  18 B and ends  19 A,  19 B is also arbitrary, and they may be interchanged without loss of generality. 
     Depending on application, low z-fold seal structures  16  may thus be provided along opposite sides  18 A and  18 B of battery case  12 , as shown in  FIG. 1 , or along opposite ends  19 A and  19 B. Alternatively, a single low z-fold seal  16  may be provided along a single side or end of battery assembly  10 , for example first side  18 A or first end  19 A, with casing  12  formed as a continuous structure along the opposite corresponding surface, for example second side  18 B or second end  19 B. 
     Connector  22  provides electrical (power) connections to battery assembly  10 , for example in a “pig tail” configuration with a connector board or manifold  23  coupled to battery assembly  10  via flex circuit  24 , as shown in  FIG. 1 . Flex circuit  24  accommodates a range of battery connection configurations and allows connector board  23  to be relocated away from battery casing  12  during wrapping and unwrapping of protective film  14 . Connector  22  also provides for a variety of different couplings to battery assembly  10 , for example along a side surface (e.g., side  18 A or  18 B) or an end surface (e.g., end  19 A or  19 B) of batter casing  12 , or at a corner interface (e.g., between side  18 A and end  19 A, as shown in  FIG. 1 ). 
     Because low z-fold seal structures  16  are provided on the side surfaces of battery assembly  10  (e.g., sides  18 A and  18 B, or ends  19 A and  19 B), and do not extend onto or above major surfaces  20 A and  20 B, the z-dimension (thickness T) of battery assembly  10  is reduced, as compared to other designs, where the seal structure or “tail” is folded over the top of the battery. That is, where seal structure  16  is not folded over onto top surface  20 A or bottom surface  20 B of battery assembly  10 , thickness T is less than in other designs, in which the seal structure extends over a portion of the top or bottom surface. Thus, the reduced z-fold configuration of  FIG. 1  provides a smaller overall battery design, as adaptable to a range of battery powered devices in which battery size is at a premium, including, but not limited to, portable electronics and mobile devices. 
     Where the total battery thickness is constrained, moreover, “fold-over” seal designs may decrease the available height (z-dimension) on the inside of the battery. Where the lateral dimensions (e.g., x and y) are held head steady, or where the lateral area is otherwise constrained, this leads to reduced interior battery volume, with a commensurate decrease in battery capacity. The reduced z-fold seal design of  FIG. 1 , on the other hand, provides battery assembly  10  with a corresponding increase in the available interior battery volume, because the seal fold does not extend over the top or bottom of battery itself; that is, seal structure  16  does not extend over top surface  20 A or bottom surface  20 B of battery assembly  10 , as described above. 
     In applications where the battery form factor (or volume envelope) is constrained, therefore, or where there is a fixed available volume (for example, in the interior of an electronic device, where space is constrained), the interior volume of battery assembly  10  may be increased in height, as compared to other designs, by the amount that the “old” tail stuck up above or below the top or bottom surface of the battery. This low z-fold seal configuration, as shown in  FIG. 1  and as further described below, thus provides battery assembly  10  with an improved size envelope and higher potential energy density, based on an increase in the available interior height and volume, as compared to the exterior size envelope. 
     In applications with a fixed available height or thickness T, for example, low z-fold seals  16  increase the available interior volume of battery assembly  10 , providing higher net energy density and a greater power/weight (or power/size) ratio, as compared to other seal configurations that increase battery height and reduce interior volume. This is particularly relevant in low-profile battery assemblies  10 , where major surfaces  20 A and  20 B are substantially larger than side surfaces  18 A,  18 B,  19 A and  19 B, and where even modest increases or decreases in absolute thickness may correspond to substantially much higher relative changes in interior volume and available anode and cathode area, with commensurate impact on battery system performance. 
     Protective wrapper or film  14  is configured to cover and protect battery assembly  10  during shipping and storage, and to retain low z-fold seal structures  16  in a generally vertical orientation against side surfaces  18 A and  18 B; that is, substantially perpendicular to major surfaces  20 A and  20 B. Protective wrapper  14  is also configured to accommodate connector  22  during installation and removal, and to provide for barcode scanning and other functions during manufacture and assembly, as described below. 
       FIG. 2  is a cross-sectional view of battery assembly  10 , taken along line  2 - 2  of  FIG. 1 . First and second portions  12 A and  12 B of battery case  12  are formed about inner battery element  28 , which stores electrical energy and provides power. Casing portions  12 A and  12 B define the major surfaces of battery  10 , for example upper and lower surfaces  20 A and  20 B, as described above. 
     In rechargeable embodiments of battery  12 , battery element  28  may typically have a jelly roll electrode structure, with a “wet” liquid or gel electrolyte interspersed between anode and cathode layers laid down on opposite surfaces of a rolled of folded plate structure, for example using intercalated lithium electrode material. Alternatively, a parallel plate (flooded electrode) structure may be used, for example with an acid electrolyte, or a post (or rod) configuration with a “dry” or paste (e.g., alkaline) electrolyte. Other types of batteries, including solid-state batteries, may be employed. 
     At least one low z-fold seal  16  is provided to seal casing portions  12 A and  12 B about inner battery element  28 , for example along opposite sides  18 A and  18 B of battery assembly  10 , as shown in  FIG. 2 . Alternatively, a single low z-fold seal  16  may be provided, for example by forming casing  12  as a flat sheet and bending the sheet around interior battery assembly  22 , with low z-fold seal structure  16  on side  18 B and with a substantially continuous casing  12  along opposite side  18 A. 
     Battery casing  12  is typically formed of a laminated material, for example an aluminum or other metal core layer  12 A (see inset) with plastic, polymer or other insulating layers  12 B and  12 C on the opposite (e.g., interior and exterior) surfaces of core layer  12 A. Typically, core layer  12 A provides strength, durability and additional structural features, while layers  12 B and  12 C provide electrical insulation and chemical protection from caustic or corrosive components of battery element  28 , for example acid or alkali electrolytes. 
     Low z-fold seals  16  are formed in a laminar, folded configuration, for example by heat sealing or bonding top and bottom (laminated) battery casings  12 A and  12 B (dashed lines) together along first or second side  18 A or  18 B of battery assembly  10 . Insulating layer or sheet  32  may be provided to cover the exposed edge of seal  16 , for example using a polyimide insulator such as a KAPTON® sheet or film, as available from E. I. du Pont de Nemours and Company of Wilmington, Del. 
     The bonded, insulated (e.g., top and bottom) battery case portions  12 A and  12 B are then bent or folded upward along the end or side surface (e.g., side  18 B) of battery assembly  10 , in a substantially vertical orientation along the +z direction (that is, along the shortest dimension or thickness, T, of battery assembly  10 ). Alternatively, seal structure  16  may be formed by bonding case portions  12 A and  12 B along the top surface of battery assembly  10 , and bending downward, in the −z direction. 
     Typically, polymer and similar insulating layers  12 B and  12 C may also provide a restoring bias to metal core layer  12 A, so that low z-fold seal structures  16  tend to migrate from a substantially vertical or perpendicular orientation to a more horizontal or parallel orientation, as defined with respect to major surfaces  20 A and  20 B of battery assembly  10 . This tendency is addressed by providing retention features to keep seal structures  16  in the substantially perpendicular orientation along the side of battery  10  during shipping and storage. 
     First, adhesive layer  34  may be provided to overcome the residual bias in battery case portions  12 A and  12 B, in order to bond seal structures  16  against sides  18 A and  18 B. Suitable materials for adhesive layer  34  include pressure sensitive adhesive (PSA) materials such as acrylics, rubber, acetate, nitrile and styrene compositions. Alternatively, other adhesive materials may be used, including, but not limited to, cyanoacrylate (CA) adhesives, epoxy resin adhesives, polymer cement materials, thermoplastics, urethane adhesives, and ultraviolet or heat-cured adhesive compounds. 
     Protective wrapper  14  may also be positioned about battery assembly  10  to protect during shipping, with overlapping layers  14 A and  14 B providing a compressive coupling to retain seal  16  in a substantially vertical orientation prior to installation. Alternatively, battery assembly  10  may be placed in a tray, shipping container or other device configured to provide a compressive coupling, as described below. 
     Protective wrapper  14  is typically formed of an insulating polymer such as a polyethylene terephthalate (PET) film, or another protective polymer wrap in sheet or film form. Low tack adhesive  30  may be provided to detachably retain wrapper  14  about battery casing  12 , so that wrapper  14  provides a compressive coupling along opposite sides  18 A and  18 B of battery assembly  10 . The compressive coupling prevents unfolding, and retains low z-fold seal structures  16  in a substantially perpendicular orientation with respect to first and second major surfaces  20 A and  20 B of battery  10 . 
     For example, wrapper  14  may be provided in two (or more) overlapping layers  14 A and  14 B, with a low-tack adhesive  30  forming a detachable bond therebetween. Alternatively, low-tack adhesive  30  may be absent, and layers  14 A and  14 B of protective wrapper  14  may be coupled with via surface forces, or a static interaction, or using a mechanical retainer. 
       FIG. 3  is a perspective view of battery assembly  10  with protective wrapper  14 , in an alternate form factor embodiment. In this particular configuration, battery assembly  10  is approximately square, with length L substantially equal to or about the same as width W, for example within ten or twenty percent. Height or thickness T is substantially less than length L and width W, as described above (that is, T&lt;&lt;L and T&lt;&lt;W). 
     In the lengthwise wrapping configuration of  FIG. 3 , protective wrapper  14  provides a compressive coupling for low z-fold seals  16  along ends  19 A and  19 B of battery assembly  10 . Protective wrapper  14  is sized with width W selected to cover most or substantially all of the top and bottom surfaces of battery assembly  10 , leaving sides  18 A and  18 B free, so that battery case  12  is uncovered or exposed in these regions. 
     As shown in  FIG. 3 , protective wrapper  14  may also be substantially transparent, or may include a substantially clear, transparent or see-through portion  14 C, in order to allow for barcode scanning and reading of other identifying indicia  36  on the outer surface (e.g., top or bottom surface) of battery assembly  10 , when film  14  is wrapped about battery cover  12 . Low tack adhesive  30  may also be provided in two or more separate layers  30  and  31 , for example with film-battery layer  30  to removably bond first (inner) layer  14 A of protective wrap or film  14  to cover  12  of battery assembly  10 , and film-film layer  31  to removable bond first (inner) layer  14 A and second (outer) layer  14 B of protective film  14 . 
     Low-tack adhesive layers  30  and  31  allow protective wrapper  14  to be attached to battery case  12  for shipping, as described above, providing compressive coupling to retain low x-fold seals  16  in a vertical orientation during shipping. Protective wrap or film  14  may also be wrapped about battery assembly  10  either in the lengthwise direction, as shown in  FIG. 3 , or in the widthwise direction, as described above with respect to  FIGS. 1 and 2 . 
     Where low-tack adhesive layers  30  and  31  are provided on either side of inner layer  14 A, protective wrapper  14  may be substantially reversible, and positionable for wrapping with either surface facing battery cover  12 . Alternatively, low-tack (battery-film) adhesive layer  131  may also be provided with substantially lower bonding strength than (film-film) adhesive layer  30 , in order to prevent discoloration or marring the outer surface of battery casing  12 . Battery-film adhesive layer  14 D may also be absent, with a static or frictional coupling between protective wrapper  14  and the outer surface of battery casing  12 . 
     Protective wrapper  14  is removable for installation, as described above, for example by pulling on tab  38  and unwrapping first and second layers  14 A and  14 B of protective wrapper  14  from battery cover  12 . Pull tab  38  may include a reduced-width portion in outer layer  14 A of protective wrapper  14 , as defined by one or more tapers  40 . Pull tab  38  may also be provided with color coding (e.g., red, yellow, blue, green, etc.), in order to provide a visual cue indicating the presence of protective wrapper  14 , and the location of pull tab  38 . 
     One or more additional cutouts or other edge features  42  may also be provided on first layer  14 B of protective wrapper  14 , adjacent battery cover  12 , in order to accommodate the pigtail or other connector  22 . Connector  22  may also be provided with connector cover  44  for additional protection during shipping, for example by attaching connector cover  44  to battery case  12  with protective wrapper  14 , or as a separately detachable element. 
       FIG. 4A  is a top perspective view of battery assembly  10  with protective wrapper  14 , in a width-wise wrapping configuration. In this configuration, protective wrapper  14  provides a compressive coupling to retain low z-fold seals  16  in a substantially vertical orientation along sides  18 A and  18 B of battery assembly  10 . Protective wrapper  14  is sized with length L selected to cover portions of, or substantially all of, the top and bottom surfaces of battery assembly  10 , along with first and second sides  18 A and  18 B. Ends  19 A and  19 B, however, may be free, with battery case  12  uncovered or exposed in these regions. 
     As shown in  FIG. 4A , protective wrapper  14  may also be removed by pulling outer layer  14 B directly away from inner layer  14 A, and then unwrapping protective wrapper  14  from cover  12  of battery assembly  10 . Thus, no separate tab feature is necessary, and outer later  14 B may or may not be color coded, depending on application. 
       FIG. 4B  is a bottom perspective view of battery assembly  10  as shown in  FIG. 4A , illustrating cutout feature  42  for a pigtail or other connector  22 . Cutout  42  is configured to space the edge of protective wrapper  14  from the connection point between connector  22  and battery assembly  10 , for example where flex circuit  24  couples to the corner interface of second side  18 B and first end  19 A, as shown in  FIG. 4B . 
     Cutout feature  42  thus prevents interference with connector  22  during installation and removal of protective wrapper  14 . In particular, flex circuit  24  allows connector board  23  to be manipulated or positioned away from battery assembly  10  during installation of protective wrapper  14 , and cutout  42  allows connector board  23  to be repositioned along side  18 B of battery assembly  10  after installation of protective wrapper  14 , without interference between the edge of protective wrapper  14  and flex circuit  24 , or the other components of connector  22 . 
     Cutout feature  42  may also be configured as a scallop, divot, groove, slot, channel or depression along a portion of length L of wrapper  14 , with or without the particular corner structure of  FIG. 4B . Thus, cutout  42  is not limited to a step configuration, where width W decreases from feature  42  in the vicinity of connector  22  to the end of wrapper  14 , but also encompasses other designs. For example, cutout feature  42  may be formed only in a region of wrapper  14  that is adjacent to connector  22 . Further, width W of wrapper  14  may decrease in the vicinity of connector  22  to form cutout  42 , and then increase back to a nominal value or to a different value along the rest of length L or wrapper  14 . The wrapping configuration may also be either lengthwise or widthwise with respect to battery assembly  10 , as described above, and the designations of length L and width W can be reversed with respect the configuration of cutout feature  42 , along either side or edge of wrapper  14 , without loss of generality. 
       FIG. 5  is a top perspective view of battery assembly  10 , positioned in shipping or storage tray  46 . Shipping tray  46  includes sides  48 A,  48 B and ends  50 A,  50 B having suitable tolerance with respect to length L and width W of corresponding sides  18 A,  18 B or ends  19 A,  19 B of battery casing  12 , in order to generate compressive coupling to retain one or more low z-fold seals  16  in a substantially vertical or perpendicular orientation with respect to the major surfaces of battery  10 . Unit  46  may also include a port, receptacle or similar feature  52  to accommodate connector  22 , for example with flex circuit  24  extending within side  48 A of shipping tray  46 , and connector board  23  extending through side  48 A at port feature  52 . 
     Tray  46  may be used in combination with protective wrapper  14 , in order to provide additional compressive retention for low z-fold seals  16  along one or more of sides  18 A,  18 B and ends  19 A,  19 B. Alternatively, battery assembly  10  may be placed in tray  46  without protective wrapper  14 , with the compressive coupling provided by selecting suitable tolerances for sides  48 A,  48 B and ends  50 A,  50 B with respect to the corresponding surfaces of battery  10 . 
       FIG. 6  is a plan view of protective film wrapper  14  for battery assembly  10 . Wrapper  14  extends from first end  52  to second end  54 , within a perimeter defined by outer edge  56 . When wrapped about a battery, first end  52  of protective wrapper  14  typically forms first (inner) layer  14 A, and second end  54  forms second (outer layer)  14 B, as described above. The designations first and second, however, are merely arbitrary, and may be interchanged without loss of generality. In addition, protective wrapper  14  may be wrapped about the battery in either orientation or direction, depending on application. 
     One or more adhesive layers may be provided to detachably retain protective wrapper  14 , for example film-film detachable adhesive layer  30  or film-battery detachable adhesive layer  31 , or both. For example, low tack adhesive may be provided in one or more layers  30  and  31 , for example film-battery or film-film layers on one or both sides of protective wrapper or film  14 , in order to removably bond wrapper  14  to the battery assembly, or to removably bond different layers of wrapper  14  together, or to perform both functions. Alternatively, one or both of low tack adhesive layers  30  and  31  may be absent, or a different adhesive material may be used. 
     Transparent window  14 C (dashed line; transparent or translucent material) may also be provided to view the surface of the battery casing, e.g., for bar code scanning or for reading an identifier or indicia, as described above. Alternatively, wrapper  14  may be transparent or translucent over substantially all or over a substantial majority of its surface area, for example over substantially all or most of the top or bottom surface of the battery assembly, or both. Wrapper  14  may also be substantially transparent over substantially all of its surface area except where color coding and other indicia are provided, for example color-coding indicia  58  on tab portion  38 . Indicia  58  may provide a color coding to indicate the presence or location of tab feature  38 , or indicia  58  may provide other identifying information such as model, size, date or serial number, and indicia  58  be located anywhere on wrapper  14 , for example at first or second end  52  or  54 , or between ends  52  and  54 . 
     One or more taper features  40  may be provided to define pull tab portion  38  of protective wrapper  14 , for example in first end  54 , as shown in  FIG. 6 . In addition, one or more tapers, ports, slots, cutouts or other edge features  42  may also be provided to space edge  56  of protective wrapper  14  from the battery connector, for example to avoid interference during installation and removal, as described above. Cutouts  42  may be provided, for example, between first end  52  and second end  54  or wrapper  14 , as shown in  FIG. 6 , or in one or both of first end  52  and second end  54 , depending on the battery size, connector location and wrapping configuration. One or more cutouts  42  may further provide a “step” feature of reduced width extending to first or second end  52  or  54  of wrapper  14 , or a more localized region of reduced width between ends  52  and  54 , for example adjacent the connector when film  14  is wrapped about a battery assembly, as described above. 
       FIG. 7  is a block diagram of method  70  for retaining low z-fold seals against the side of a battery assembly. Method  70  comprises forming a battery case (step  71 ), bonding the battery case to form a seal (step  72 ), bending the seal into a substantially perpendicular orientation (step  73 ), and retaining the seal against the side of the battery (step  74 ). 
     Forming the battery case (step  71 ) comprises forming first and second portions of the case about a battery element. The first and second casing portions define first and second major surfaces of the battery, for example top and bottom surfaces. The sides of the battery extend between the first and second major surfaces. 
     Bonding the battery case (step  72 ) comprises bonding the first and second casing portions together along a selected side, in order to form a seal structure. The bonding may be performed, for example, by heat treatment or thermal bonding, or using an adhesive or mechanical attachment. 
     Bending the seal (step  73 ) comprises bending the seal into a substantially vertical or perpendicular orientation with respect to the first and second major surfaces of the battery. Thus, the seal structure is oriented substantially parallel to the selected side. The seal may also be provided with an insulating material such as a KAPTON® or polyimide sheet, in order to cover the exposed edge. 
     Retaining the seal (step  74 ) comprises retaining the seal structure in the substantially perpendicular orientation with respect to the selected side. Retention may be accomplished, for example, by use of a contact adhesive, glue, epoxy or other adhesive material to bond the seal structure to the selected side. 
     Method  70  may also include wrapping the battery casing with a protective film (step  75 ). The protective film forms a compressing coupling to retain the seal in the substantially perpendicular orientation along and against the selected side of the battery, so that the residual bias in the casing material is overcome, and the form factor of the battery is preserved. 
     Wrapping the battery casing may include positioning a cutout with respect to a connector on the battery, so that an edge of the protective film is spaced from the connector. The cutout is configured to avoid interference while repositioning the battery connector during installation and removal of the protective film. 
     Generally, the adhesive film remains in place for a substantial time during storage and shipment (step  76 ), allowing the adhesive to set sufficiently to overcome any residual bias in the battery casing. Thus, the seal structure is retained against the selected side of the battery even after unwrapping the protective film (step  77 ). As a result, the seal structure remains in the substantially perpendicular orientation during installation (step  78 ) and use, for example in a portable electronic device or mobile phone. 
     The battery assembly may also be placed in a shipping tray or storage unit (step  79 ). The storage unit maintains a tightly selected tolerance with respect to the battery casing, generating a compressive coupling to retain the seal structure against the selected side. The battery may be wrapped first, before placement into the shipping or storage tray, or the battery may be unwrapped, so that the storage unit provides the primary compressive coupling to retain the seal structure against the side of the battery while the adhesive sets. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. In other instances, well known circuits and devices are shown in block diagram form in order to avoid unnecessary distraction from the underlying invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.

Metadata:
Filing Date: 20120830
Publication Date: 20171107
Grant Date: 20171107
Priority Date: 20120830
Inventors: WERNER CHRISTOPHER M.
MANULLANG TYSON B.
STEPHENS GREGORY N.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01M50/121", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/186", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2/0408", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1043", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/0292", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/0207", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M2/0267", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/121", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/186", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/1245", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M50/124", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1043", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1043", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 50188018