Systems and methods for battery control circuits

Abstract

An electronic device may include a battery and a battery case member that fixes the battery. The battery case member may have a polymer base layer and a metal coating covering at least a portion of a surface of the polymer base layer. A method for manufacturing a battery case member may include 1) providing a polymeric base layer dimensioned to abut a battery in an electronic device, 2) etching a surface of the polymeric base layer, and 3) depositing a metal coating over at least a portion of the surface of the polymeric base layer. Various other methods, systems, and devices are also disclosed.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Application No. 63 / 658,036 filed on June 10, 2024, U.S. Application No. 63 / 674,332 filed on July 23, 2024, U.S. Application No. 63 / 674,335 filed on July 23, 2024, U.S. Application No. 63 / 671,918 filed on July 16, 2024, U.S. Application No. 18 / 788,255 filed on July 30, 2024, and U.S. Application No. 63 / 589,554 filed on October 11, 2023, the disclosures of each of which are incorporated by reference in their entirety. Technical Field

[0003] The present disclosure generally relates to battery assemblies having non-rectangular surfaces and contours. Background Art

[0004] Batteries are widely used in various consumer devices, including portable products and wearable products. The battery box in or on the device is usually used to safely accommodate and protect the battery and the device connected to the battery and the user of such device. In order to protect the device and the user from harm, this battery box is usually designed to have a combination of high rigidity, high strength and fire resistance. Metals (such as steel and aluminum) are usually selected as the shell for traditional batteries because they can be manufactured to meet each of these design requirements, and they usually have high-quality surface finishes. In devices with weight restrictions, lightweight metals (such as aluminum) can be selected. Metal battery boxes are usually designed to accommodate batteries with relatively simple shapes (such as rectangular block shapes). Battery boxes for such shapes can easily be manufactured by, for example, stamping to produce thin, lightweight shells. However, more complex shapes may be difficult to manufacture without cracking and / or wrinkling, especially when requiring thinner wall thickness to adapt to lower weight requirements. Although some materials (such as carbon fiber) can overcome some of the above-mentioned problems, the cost of using such materials in various electronic products may be prohibitively high. Summary of the invention

[0005] According to a first aspect of the present disclosure, a battery assembly is provided, comprising: a battery enclosure component, the dimensions of which are configured to secure a battery in an electronic device, the battery enclosure component comprising: a polymer base layer; and a metal coating, the metal coating covering at least a portion of a surface of the polymer base layer.

[0006] According to a second aspect of the present disclosure, an electronic device is provided, comprising: a battery; and a battery housing member that fixes the battery, the battery housing member comprising: a polymer base layer; and a metal coating that covers at least a portion of a surface of the polymer base layer.

[0007] According to a third aspect of the present disclosure, a method is provided, comprising: providing a polymer base layer, the size of which is set to be adjacent to a battery in an electronic device; etching a surface of the polymer base layer; and depositing a metal coating over at least a portion of the surface of the polymer base layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings illustrate several exemplary embodiments and are a part of the specification. Together with the following description, these drawings illustrate and explain various principles of the present disclosure.

[0009] Figure 1A is a perspective view of an exemplary battery housing member according to some embodiments.

[0010] Figure 1B According to some embodiments Figure 1A A side view of a battery housing component is shown in FIG.

[0011] Figure 2A According to some embodiments Figure 1A A top view of a battery housing component is shown in FIG.

[0012] Figure 2B is a perspective view of an exemplary battery assembly according to some embodiments.

[0013] Figure 3 is a diagram of an exemplary substrate member supported on a metal plating jig for manufacturing a battery housing member according to some embodiments.

[0014] Figure 4A A top view of an exemplary temple for a head-mounted display device according to some embodiments.

[0015] Figure 4B According to some embodiments Figure 4A A side view of the frame is shown in FIG.

[0016] Figure 5A is a graph showing flexural strength values ​​for various materials according to some embodiments.

[0017] Figure 5B To illustrate the Figure 5A A graph showing the Young's modulus values ​​of the materials.

[0018] Fig. 6A is a cross-sectional view of a portion of a polymer-based layer according to some embodiments.

[0019] Figure 6B According to some embodiments, after etching Fig. 6A A cross-sectional view of a portion of a polymer base layer is shown in FIG.

[0020] Figure 6C According to some embodiments, after electroless deposition Figure 6B A cross-sectional view of a portion of a polymer base layer is shown in FIG.

[0021] Fig. 7A According to some embodiments Figure 6C A cross-sectional view of a portion of a polymer-based layer coated with a first metal layer is shown in FIG.

[0022] Figure 7B According to some embodiments Fig. 7A 0047] A cross-sectional view of a portion of a coated polymer-based layer is shown in FIG. , wherein a second metal layer is disposed on the first metal layer.

[0023] Figure 8 According to some embodiments Figure 7B A cross-sectional view of a portion of a coated polymer base layer is shown in FIG. , wherein a top coating layer is disposed on a second metal layer.

[0024] Fig. 9 is a cross-sectional view of a portion of a polymer-based layer having a metal coating disposed on two opposing surfaces, according to some embodiments.

[0025] Fig.10 is a flow chart of an exemplary method for manufacturing a battery housing member according to some embodiments.

[0026] Fig.11 is an illustration of exemplary augmented reality glasses that may be used in conjunction with embodiments of the present disclosure.

[0027] Fig.12 is an illustration of an exemplary virtual reality headset that may be used in conjunction with embodiments of the present disclosure.

[0028] Fig.13 A block diagram illustrating firmware control flow for managing headroom control according to some embodiments.

[0029] Fig.14 is a flow diagram illustrating firmware control flow for managing headroom control according to some embodiments.

[0030] Fig.15is a block diagram illustrating firmware control flow for managing battery voltage over time according to some embodiments.

[0031] Fig.16 FIG. 5 is a graph showing a fixed boost voltage relative to a regulated boost voltage of a battery voltage according to some embodiments.

[0032] Fig.17 is a diagram illustrating a hardware protection layer according to some embodiments.

[0033] Fig.18 is a block diagram illustrating an overcurrent protection circuit according to some embodiments.

[0034] Fig.19 is an illustration of an exemplary logic timing diagram according to some embodiments.

[0035] Fig. 20 To illustrate the relative capacity versus time of exposure to high temperature according to some embodiments.

[0036] Fig.21 is an illustration of an exemplary heat map according to some embodiments.

[0037] Fig. 22 2 is a graph showing threshold numbers corresponding to different exposure levels according to some embodiments.

[0038] Fig.23 is an illustration of an exemplary timing diagram according to some embodiments.

[0039] Fig.24 is a block diagram illustrating electronic components within a battery pack according to some embodiments.

[0040] Fig.25 is a diagram of an exemplary pouch cell battery according to some embodiments.

[0041] Fig.26 is an illustration of an exemplary pouch cell battery having two or more battery cells according to some embodiments.

[0042] Fig. 27 is an illustration of an exemplary pouch cell battery having two or more stacked battery cells according to some embodiments.

[0043] Throughout the drawings, the same reference numerals and descriptions indicate similar but not necessarily identical elements. Although the exemplary embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown in the drawings by way of embodiment and will be described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to the specific forms disclosed. On the contrary, the present disclosure encompasses all modifications, equivalents, and alternatives that fall within the scope of the appended claims. DETAILED DESCRIPTION

[0044] Battery assembly having a metal-coated polymer housing member

[0045] Batteries are widely used in various consumer devices, including portable products and wearable products. The battery box in or on the device is usually used to safely accommodate and protect the battery and the device connected to the battery and the user of such device. In order to protect the device and the user from harm, this battery box is usually designed to have a combination of high rigidity, high strength and fire resistance. Metals (such as steel and aluminum) are usually selected as the shell for traditional batteries because they can be manufactured to meet each of these design requirements, and they usually have high-quality surface finish. In devices with weight restrictions, lightweight metals (such as aluminum) can be selected. Metal battery boxes are usually designed to accommodate batteries with relatively simple shapes (such as rectangular block shapes). Battery boxes for such shapes can easily be manufactured by, for example, stamping to produce thin, lightweight shells. However, more complex shapes may be difficult to manufacture without cracking and / or wrinkling, especially when thinner wall thickness is required to adapt to lower weight requirements. Although some materials (such as carbon fiber) can overcome some of the above-mentioned problems, the cost of using such materials in various electronic products may be prohibitively high.

[0046] The present disclosure generally relates to battery assemblies having non-rectangular surfaces and profiles. The housing for the disclosed battery assembly can be formed of a molded polymer material that is plated with one or more thin metal layers. The combination of polymer and metal materials can provide a relatively lightweight and thin solid housing with a high bending modulus and Young's modulus. In addition, the described housing can be fire-resistant and can have a visually attractive metal surface finish. The cost of polymer and metal materials can be much lower than other strong, lightweight materials (such as carbon fiber layers). As described herein, the housing can be molded into a much more complex shape than a traditional battery housing. Therefore, such a housing can have a variety of curved surfaces with non-rectangular surface profiles.

[0047] Features from any of the embodiments described herein may be used in combination with each other according to the general principles described herein. These and other embodiments, features and advantages will be more fully understood by reading the following detailed description in conjunction with the accompanying drawings and claims.

[0048] The following will refer to Figures 1A to 9 A detailed description of exemplary systems and devices including battery assemblies is provided. Fig.10 The corresponding discussion will provide examples of methods for making the systems and devices presented herein. Figure 11 to Figure 12 The description will provide examples of various systems and devices that implement the embodiments presented herein.

[0049] Figures 1A to 2A An exemplary battery housing member 100 is shown, which is sized to secure a battery in an electronic device. The battery housing member 100 can be configured to at least partially surround a battery having a non-rectangular and / or other unconventional shape. For example, the battery housing member 100 can include one or more curved bottom walls 102, each having a curved surface shape configured to abut a curved battery surface. The outer contour of the battery housing member 100 can enable it to be installed in a variety of electronic devices and conform to the various electronic devices. For example, in some embodiments, the battery housing member 100 can secure the battery in a curved battery pack attachment for a head-mounted display device. In at least one example, such a curved battery pack attachment can be curved so as to tightly surround the user's head when the head-mounted display device is worn. The curved battery pack attachment can be located on any suitable portion of the head-mounted display system. For example, the curved battery pack attachment can be provided on a head strap assembly that, when worn, will keep the head-mounted display device firmly on the user's head so that the battery pack attachment is close to the back of the user's head.

[0050] The battery housing member 100 may also include a side wall 104 extending from a peripheral area of ​​the curved bottom wall 102, so that the curved bottom wall 102 and the side wall 104 together define one or more battery recesses 106. The side wall 104 may have any suitable shape and orientation. For example, the exposed edge of the side wall 104 may generally or substantially follow a path parallel to the surface and / or edge portion of the curved bottom wall 102, so that the side wall 104 has a substantially or substantially uniform width around the battery recess 106. In some examples, the side wall 104 may extend from the curved bottom wall 102 at different angles. For example, the side wall 104 may extend in a generally normal direction to the adjacent surface area of ​​the curved bottom wall 102, so that the side wall 104 may be oriented differently due to the surface curvature of the curved bottom wall 102.

[0051] In various examples, the battery recess 106 can be configured to at least partially surround the bottom surface and side surfaces of one or more batteries disposed within the battery housing member 100. In some examples, the battery housing member 100 may include an intermediate region 108 disposed between a pair of battery recesses 106. Each battery recess 106 can at least partially surround a separate battery and / or a separate portion of a battery. The intermediate region 108 can protrude from the curved bottom wall 102 to separate adjacent battery recesses 106. In some examples, the intermediate region 108 can provide structural support for electronic components (such as circuit boards and / or cables) coupled to the batteries disposed within the battery recesses 106.

[0052] In various embodiments, the battery housing member 100 may also include at least one mounting extension 110 protruding from the exterior of the side wall 104. For example, Figure 1A and Figure 1B As shown in , the battery housing member 100 may include two mounting extensions 110 extending from opposite end regions of the battery housing member 100. One or more mounting holes 112 may be defined in each mounting extension 110. The mounting holes 112 can be used as a racking point to securely hold the battery housing member 100 in a desired position during processing. For example, a fastener can be attached to the mounting extension 110 via the mounting hole 112 to securely fix the battery housing member 100 to a suitable retaining bracket during the metal coating process. Additionally or alternatively, in some examples, the mounting extension 110 and / or the mounting hole 112 can be used to fasten the battery housing member 100 to a display device assembly, such as a headband assembly.

[0053] Figure 2BAn exemplary curved battery assembly 200 is shown. In some examples, the battery assembly 200 may include a pair of curved batteries 202, a printed circuit board 206, a ribbon cable 210, and at least one connector 212. In alternative embodiments, the battery assembly 200 may include a single curved battery or more than two curved batteries. In some embodiments, the battery assembly 200 may provide a primary power source or an auxiliary power source to an electronic device (such as a head-mounted display device). In some embodiments, the battery assembly 200 may receive and supply power through one connector (e.g., connector 212) and transmit power through another connector. In other embodiments, the battery assembly 200 may receive and transmit power through a single connector. In some embodiments, the battery assembly 200 may act as a power conduit to relay power to a connected device. In some embodiments, the printed circuit board 206 may include a circuit configured to charge the curved battery 202 and / or relay power from the batteries 202 and 204 to a connected helmet display system. In some embodiments, the printed circuit board 206 may represent a protection control module or a protection circuit module.

[0054] As shown, the curved battery 202 may have a curved inner surface 203 and an outer surface 205. In at least one embodiment, the curved inner surface 203 and the outer surface 205 of each of the batteries 202 and 204 may be substantially parallel to each other. In some examples, the curved inner surface 203 and / or the curved outer surface 205 of the battery 202 may conform to a curve having a uniform or constant radius of curvature. Additionally or alternatively, one or more curved inner surfaces 203 and / or curved outer surfaces 205 may conform to a curve having an uneven or varying radius of curvature. In some embodiments, the curved inner surface 203 and the curved outer surface 205 may have a radius of curvature within the range of 90 mm-120 mm (e.g., 95 mm or 110 mm). In some embodiments, the curved inner surface 203 and / or the curved outer surface 205 may be a spline surface. In some examples, the term "spline surface" may refer to any curved surface that can be modeled or represented using one or more spline curves. In some examples, the term "spline curve" may refer to an approximation curve passing near one or more control points. Additionally or alternatively, the term "spline curve" may refer to an interpolating curve passing through one or more control points. In some examples, the term "spline curve" may refer to a complex or piecewise polynomial curve consisting of two or more curve segments.

[0055] The curved battery assembly 200 can have any suitable length, width, or thickness, and / or can be optimized for a particular use of the curved battery assembly 200. In some embodiments, the curved battery assembly 200 can have a length 116 in the range of 60 mm-100 mm or in the range of 70 mm-80 mm, a width 118 in the range of 35 mm-45 mm, and a thickness in the range of 4-7 mm. In some examples, the curved battery assembly 200 can be a curved lithium-ion cell.

[0056] In some embodiments, the curved battery assembly 200 can be constructed to have a rigid and / or substantially rigid structure. Alternatively, the curved battery assembly 200 can be constructed to have a flexible and / or substantially flexible structure. In some embodiments, a plurality of rigid curved units can be combined to give the curved battery a flexible and / or substantially flexible structure. In some embodiments, a plurality of rigid curved units can be connected by a flexible connector (e.g., a hinge connector). By having an uneven curvature, the curved battery assembly 200 can better conform to the user's body. In some embodiments, the curved battery assembly 200 can have a conformal structure that matches or approximates the shape of one or more users' heads (e.g., forehead, back of the head, etc.).

[0057] According to various embodiments, the battery housing member 100 can partially surround and contain the curved battery assembly 200. The battery housing member 100 can be sized and have sufficient rigidity and strength to securely hold the components of the curved battery assembly 200. For example, the curved bottom wall 102 of the battery housing member 100 can be shaped and configured to abut against the outer surfaces 205 of the curved batteries 202 and 204. The side walls 104 of the battery housing member 100 can be shaped and configured to abut against and at least partially surround the side regions of the curved battery assembly 200, including the corresponding side surfaces of the curved batteries 202 and 204. The intermediate region 108 can protrude a distance from the battery recess 106 to provide a surface that abuts and secures a portion of the curved battery assembly 200 (such as a printed circuit board 206).

[0058] Figure 3 A system 300 for processing a substrate member to produce a battery housing member is shown according to some embodiments. As shown, a substrate member 314 can be used as a base member (i.e., a substrate member) that can be plated or coated with a material such as one or more metals or other suitable material layers to form a battery housing member, such as Figures 1A to 2A. As shown, the substrate member 314 can be formed into a selected shape before processing, such as conforming to the shape of the battery housing member 100. In at least one example, the substrate member 314 can be a plastic member that has been molded into a specified shape.

[0059] During processing, the substrate member 314 can be fixed to the fixture 318, for example. The support member 316 can be fastened to the substrate member 314 and the support member 316 to hold the substrate member 314 during processing. For example, the support member 316 can be coupled to the substrate member 314 via the mounting hole 312, which can be located at the peripheral area of ​​the substrate member 314. Once mounted to the fixture 318, the substrate member 314 can be processed in any suitable manner. For example, as described in more detail below, the substrate member 314 can be etched and plated with one or more metal layers. In at least one example, after the etching process, the substrate member 314 can be subjected to an electroplating process to deposit one or more layers of at least one metal material onto the surface of the substrate member 314. In some examples, the fixture 318 and the support member 316 can be conductive to provide an electric charge to a portion of the substrate member 314 and / or one or more layers deposited on the substrate member 314 for electroplating.

[0060] In some examples, the substrate member 314 can be secured to the fixture 318 to prevent warping and / or other deformation during processing. For example, sufficient tension can be applied to the substrate member 314 via, for example, the mounting holes 312 to prevent deformation of the substrate member 314. Additionally or alternatively, supports and / or additional connection points can be used to maintain the substrate member 314 in a desired shape and configuration during processing. According to some examples, the fixture 318 and / or additional portions of the system 300 can be configured to disperse current at portions of the substrate member 314 (such as sharp edges and / or corner areas) to prevent excessive deposition and / or accumulation of metal material in these areas during a deposition process (such as an electroplating process).

[0061] Figure 4A and Figure 4B An exemplary frame arm 420 for a head mounted device, such as a pair of augmented reality glasses, is shown. The frame arm 420 may include a battery secured within the frame arm 420 by a battery housing member 424. Figure 4A and Figure 4BAs shown, the battery housing member 424 can be coupled to the housing 422 of the frame arm 420, wherein the battery housing member 424 forms a cover that securely holds and covers the battery within the housing 422. The battery housing member 424 may include any suitable material as described herein. For example, the battery housing member 424 may include a polymer substrate coated with one or more deposited layers, such as an electrodeposited metal layer. Other portions of the frame arm 420 may include any suitable material, such as a polymer, a composite material (e.g., carbon fiber), and / or other suitable materials that provide sufficient structural rigidity and support for a frame worn by a user.

[0062] The battery housing member 424 can be configured to at least partially surround a battery having a non-rectangular and / or other unconventional shape. For example, the battery housing member 424 may include one or more curved surfaces configured to closely abut and securely hold a battery having curved and / or other non-linear surface features. The outer contour of the battery housing member 424 can enable it to be mounted within and conform to the corresponding features of the frame arm 420. In various examples, the battery housing member 424 may include mounting holes and / or other features (e.g., etching, plating, etc.) that can be used to process the battery housing member 424 and / or fix the battery housing member 424 to the housing 422 of the frame arm 420.

[0063] Figure 5A Graph 502 is shown showing flexural strength values ​​for various materials according to some embodiments. Figure 5B To show Figure 5A 504 of Young's modulus values ​​of materials shown in FIG. 504. According to some embodiments, for battery housing components (e.g., Figures 1A to 2B The battery housing member 100 and Figure 4A and Figure 4B The material of the battery housing member (in the battery housing) may include a combination of properties that provide the component with sufficient strength and rigidity while reducing weight and size compared to traditional housing materials.

[0064] Figure 5BGraph 502 in FIG. 5 shows flexural strength values ​​in megapascals per gram (MPa / g) for various materials and material combinations, including ABS (acrylonitrile butadiene styrene), 1.5K PC+CF (1.5K polycarbonate and carbon fiber), PA6+CF (polyamide6and carbon fiber), PA6+3K (polyamide 6and 3K carbon fiber), ABS+Co (acrylonitrile butadiene styrene plated with cobalt), and ABS+NiCo (acrylonitrile butadiene styrene plated withNickel-Cobalt). Figure 5B Graph 504 in FIG. 5 shows Young's modulus values ​​for the materials and material combinations shown in graph 502 in GPa / g. Figure 5A and Figure 5B As shown in , the electroplated ABS material includes ABS+Co and ABS+NiCo materials, which have an excellent combination of high bending strength and high Young's modulus. Therefore, compared with traditional housing materials, the electroplated ABS material can provide the required combined strength and deformation resistance in devices such as the disclosed battery housing.

[0065] FIG. 6A to FIG. 8 An example process for etching and plating a substrate (such as a polymer base) to make a plated component (such as a battery housing component described herein) is shown. The polymer base of the plated component (such as a battery housing component) can be plated with a metal material or a combination of materials on the outer surface of the component so that all or substantially all surfaces are covered with a metal plating layer. In some embodiments, selected surfaces and areas can be plated while other surfaces and areas are not plated.

[0066] Fig. 6A A substrate member (eg, Figure 3 630. As shown, the portion of the polymer base layer 630 may include a substrate surface 632, which may be an exposed molded surface portion of the substrate member. The polymer base layer 630 may include any suitable material or combination of materials. For example, the polymer base layer 630 may include a polymer material such as ABS and / or any other suitable polymer material.

[0067] Figure 6B A cross-sectional view of the polymer base layer 630 after etching is shown. According to some examples, Fig. 6A The substrate surface 632 shown in the figure can be etched to form grooves 636 in the polymer base layer 630, and the raised portions 634 between the grooves define the outer surface boundary of the polymer base layer 630. Etching can be performed in any suitable manner to define the grooves 636 in the polymer base layer 630. For example, chemical etching can be used to remove portions of the polymer base layer 630 to form grooves 636 in the etched area. Chemical etching can be performed with or without a mask. Chemical etching can be performed using any suitable etchant, including, for example, acid solutions (e.g., sulfuric acid solutions, chromium sulfur solutions, etc.). Any other suitable type of wet and / or dry etching can be used in addition or alternatively to define the grooves 636 in the polymer base layer 630. For example, photoetching, laser etching, gas etching, plasma etching and / or any other suitable etching technology can be used. The uneven surface of the polymer base layer 630 including the grooves 636 and the raised portions 634 can provide features on the surface for fixing the deposited metal layer to the polymer base layer 630.

[0068] Figure 6C A cross-sectional view of a polymer base layer 630 after electroless nickel plating is shown. As shown, the grooves 636 and raised portions 634 of the polymer base layer 630 can be coated with an electroless deposited layer 638 (such as a nickel layer). For example, the electroless deposited layer 638 can be deposited by immersing the polymer base layer 630 in a plating solution including a metal ion source (such as nickel ions), a reducing agent (e.g., formaldehyde, hydrazine, hydroxylamine, etc.). The deposited nickel layer 638 can be thin enough to cover a surface portion of the polymer base layer 630 without completely filling or covering the grooves 636, thereby allowing further deposition of material (such as copper) within the grooves 636.

[0069] Fig. 7A 630 after electrodeposition of a copper layer. A suitable metal (such as copper) may be deposited on a surface portion of the polymer base layer 630 by an electrodeposition process. According to at least one embodiment, the polymer base layer 630 may be impregnated with a metal including copper ions (e.g., Cu 2+ ) in an electrolytic electrodeposition solution. An anode (such as a copper anode) can be connected to a power source and can be immersed in the solution. The electroless deposited layer 638 (see Figure 6C ) can be connected to a power source and can act as a cathode (e.g., the terminals of the power source can be electrically coupled to the nickel-plated polymer base layer 630 via the clamp 318 and the support member 316, as shown Figure 3When a charge is applied to the immersed anode and cathode (i.e., the electroless deposited layer 638) by a power source, copper ions in the electrodeposition solution can migrate and deposit on the electroless deposited layer 638. Fig. 7A A copper layer 740 and a polymer base layer 630 are formed on the substrate (not shown).

[0070] In some embodiments, the electrodeposition process can be performed for a period of time sufficient to cover the grooves 636 and the protrusions 634 of the polymer base layer 630. In at least one example, after deposition, the grooves 636 can be substantially or completely filled with the deposited copper layer 740, so that the copper layer 740 forms a layer over the grooves 636 and the protrusions 634, and the copper layer has a uniform or substantially uniform exposed surface 741, such as Fig. 7A The portion of copper layer 740 adjacent to polymer base layer 630 may be secured within recess 636 such that the portion of copper layer 740 is inserted into the portion of recess 636 .

[0071] Figure 7B A cross-sectional view of the polymer-based layer 630 and the copper layer 740 after depositing the nickel-containing layer is shown. In some examples, a metal layer 742, such as a layer including a cobalt alloy (e.g., a cobalt-phosphorus alloy), a nickel alloy (e.g., a nickel-cobalt alloy), a magnesium alloy, an aluminum alloy, and / or any other suitable metal and / or alloy, can be electroplated on a surface 741 of the copper layer 740.

[0072] The metal layer 742 can be electroplated onto the copper layer 740 in any suitable manner. In at least one embodiment, the metal layer 742 can be electroplated onto the copper layer 740 via electrodeposition. According to at least one embodiment, the polymer base layer 630 plated with the copper layer 740 can be immersed in an electrolytic electrodeposition solution including ions that form an alloy (e.g., cobalt ions, phosphorus ions, nickel ions). The anode can be connected to a power source and can be immersed in the solution. The copper layer 740 can be connected to a power source and can act as a cathode (e.g., the terminals of the power source can be electrically coupled to the copper layer 740 via the clamp 318 and the support member 316, as shown in FIG. Figure 3 When a charge is applied to the immersed anode and cathode (ie, copper layer 740) by a power source, ions in the electrodeposition solution can migrate and deposit onto copper layer 740, forming metal layer 742 over copper layer 740 and polymer-based layer 630.

[0073] Figure 8A cross-sectional view of the metal layer 742 after the outer layer is deposited is shown. In at least one example, a top coating 744 can be deposited onto the metal layer 742. The top coating 744 can be formed on the metal layer 742 in any suitable manner and can include any suitable material and / or combination of materials. The top coating 744 can provide functional and / or aesthetic properties to modify the exposed surface portion of the resulting electroplated component (such as a battery housing component) in a desired manner.

[0074] Fig. 9 A cross-sectional view of a portion of a plated component 900, such as a portion of a battery housing component, is shown. The base layer may be plated on any suitable portion and may include plating on one or both sides of the layer. For example, Fig. 9 As shown, the polymer base layer 930 may include deposited metal layers on both sides. In some examples, the polymer base layer 930 may include first metal layers 932A and 932B (e.g., copper layers) deposited on the top surface and the bottom surface, respectively. In addition, second metal layers 934A and 934B (e.g., alloy layers, such as cobalt-phosphorus alloy, nickel-cobalt alloy, etc.) may be electroplated on the first metal layers 932A and 932B, respectively.

[0075] The polymer base layer 930, the first metal layers 932A and 932B, and the second metal layers 934A and 934B can have any suitable thickness. The layers, materials, and thicknesses of the electroplated component 900 can be selected to provide a selected combination of strength and weight. For example, the polymer base layer 930 can have a thickness T1 of about 100 μm to about 500 μm (e.g., about 100 μm, about 110 μm, about 120 μm, about 130 μm, about 140 μm, about 150 μm, about 160 μm, about 170 μm, about 180 μm, about 190 μm, about 200 μm, about 210 μm, about 220 μm, about 230 μm, about 240 μm, about 250 μm, about 260 μm, about 270 μm, about 280 μm, about 290 μm, about 300 μm, about 310 μm, about 320 μm, about 330 μm, about 340 μm, about 350 μm, about 360 μm, about 370 μm, about 380 μm, about 390 μm, about 400 μm, about 410 μm, about 420 μm, about 430 μm, about 440 μm, about 450 μm, about 460 μm, about 470 μm, about 480 μm, about 490 μm, about 500 μm, about 510 μm, about 520 μm, about 530 μm, about 540 μm, about 550 μm, about 560 μm, about 570 μm, about 580 μm, about , about 280μm, about 290μm, about 300μm, about 310μm, about 320μm, about 330μm, about 340μm, about 350μm, about 360μm, about 370μm, about 380μm, about 390μm, about 400μm, about 410μm, about 420μm, about 430μm, about 440μm, about 450μm, about 460μm, about 470μm, about 480μm, about 490μm, about 500μm).

[0076] The first metal layer and the second metal layer (e.g., the first metal layer 932A and the second metal layer 934A) can have a combined thickness of about 0.3 μm to about 500 μm. In some examples, the first metal layers 932A and 932B can each have a thickness T2 of about 0.3 μm to about 30 μm (e.g., about 0.3 μm, about 0.4 μm, about 0.5 μm, about 0.6 μm, about 0.7 μm, about 0.8 μm, about 0.9 μm, about 1 μm, about 2 μm, about 3 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, about 11 μm, about 12 μm, about 13 μm, about 14 μm, about 15 μm, about 16 μm, about 17 μm, about 18 μm, about 19 μm, about 20 μm, about 21 μm, about 22 μm, about 23 μm, about 24 μm, about 25 μm, about 26 μm, about 27 μm, about 28 μm, about 29 μm, about 30 μm, about 31 μm, about 32 μm, about 34 μm, about 35 μm, about 36 μm, about 37 μm, about 38 μm, about 39 μm, about 40 μm, about 41 μm, about 42 μm, about 43 μm, about 44 μm, about 45 μm, about 46 μm, about 47 μm, about 48 μm, about 49 μm, about 50 μm, about 51 μm, about 52 μm, about 53 μm, about about 9μm, about 10μm, about 11μm, about 12μm, about 13μm, about 14μm, about 15μm, about 16μm, about 17μm, about 18μm, about 19μm, about 20μm, about 21μm, about 22μm, about 23μm, about 24μm, about 25μm, about 26μm, about 27μm, about 28μm, about 29μm, about 30μm).

[0077] The second metal layers 934A and 934B may each have a thickness T3 of about 1 μm to about 500 μm (e.g., about 1 μm, about 2 μm, about 3 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 60 μm, about 70 μm, about 80 μm, about 90 μm, about 100 μm, about 110 μm, about 120 μm, about 130 μm, about 140 μm, about 150 μm, about 160 μm, about 170 μm, about 180 μm). , about 190μm, about 200μm, about 210μm, about 220μm, about 230μm, about 240μm, about 250μm, about 260μm, about 270μm, about 280μm, about 290μm, about 300μm, about 310μm, about 320μm, about 330μm, about 340μm, about 350μm, about 360μm, about 370μm, about 380μm, about 390μm, about 400μm, about 410μm, about 420μm, about 430μm, about 440μm, about 450μm, about 470μm, about 480μm, about 490μm, about 500μm).

[0078] In some embodiments, a single layer of material (eg, copper) may be disposed on one or both sides of the polymer base layer 930 . Such a layer can have, for example, a thickness of about 0.3 μm to about 500 μm (e.g., about 0.3 μm, about 0.4 μm, about 0.5 μm, about 0.6 μm, about 0.7 μm, about 0.8 μm, about 0.9 μm, about 1 μm, about 2 μm, about 3 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 60 μm, about 70 μm, about 80 μm, about 90 μm, about 100 μm, about 110 μm, about 120 μm, about 130 μm, about 140 μm, about 150 μm, about 160 μm, about 0μm, about 170μm, about 180μm, about 190μm, about 200μm, about 210μm, about 220μm, about 230μm, about 240μm, about 250μm, about 260μm, about 270μm, about 280μm, about 290μm, about 300μm, about 310μm, about 320μm, about 330μm, about 340μm, about 350μm, about 360μm, about 370μm, about 380μm, about 390μm, about 400μm, about 410μm, about 420μm, about 430μm, about 440μm, about 450μm, about 460μm, about 470μm, about 480μm, about 490μm, about 500μm).

[0079] Fig.10 FIG. 1 is a flow chart of an exemplary method 1000 for manufacturing an electroplated component, such as a battery housing component, according to some embodiments. Fig.10 As shown, at step 1010, a polymer substrate may be provided. The polymer substrate may be sized to abut a battery in an electronic device. In some examples, the polymer substrate may be molded so that a surface of the polymer substrate includes one or more curved portions (e.g., see Figures 1A to 2A ).

[0080] exist Fig.10 At step 1020 in the method, the surface of the polymer base layer can be etched. For example, the polymer base layer can be etched using suitable wet and / or dry etching techniques to produce uneven surface features, such as grooves on the exposed surface portion of the polymer base layer (e.g., see FIG. 6A to FIG. 6B ).

[0081] exist Fig.10 At step 1030 in the embodiment of the present invention, a metal coating may be deposited over at least a portion of the surface of the polymer base layer. For example, one or more metal layers (e.g., see FIG. 6C to FIG. 9). In some examples, depositing the metal coating may include 1) depositing a first metal layer over the etched surface of the polymer base layer, and 2) depositing a second metal layer over the first metal layer, the second metal layer comprising an alloy (e.g., see FIG. 7A to FIG. 9 ). In some examples, the second metal layer may include at least one of a cobalt-phosphorous alloy or a nickel-cobalt alloy.

[0082] As described herein, the disclosed battery assembly advantageously includes a housing formed of a molded polymer material that is electroplated with one or more thin metal layers. The combination of polymer and metal materials can provide a relatively lightweight and thin strong housing with a high bending modulus and Young's modulus. In addition, the described housing can provide fire resistance while also presenting a visually attractive metallic surface finish. The cost of the combination of polymer and metal materials can be much lower than other strong, lightweight materials (such as carbon fiber layers). The battery housing can be molded into a shape that is much more complex than a traditional rectangular battery housing. Therefore, such a housing can have a variety of curved surfaces with non-rectangular surface profiles to accommodate batteries for devices with reduced device profiles and unique profiles.

[0083] Example Implementation

[0084] Embodiment 1: A battery assembly includes a battery housing member sized to secure a battery in an electronic device, the battery housing member including 1) a polymer base layer and 2) a metal coating covering at least a portion of a surface of the polymer base layer.

[0085] Embodiment 2: The battery assembly of embodiment 1, wherein the surface of the polymer base layer comprises an etched surface.

[0086] Embodiment 3: The battery assembly according to any one of Embodiments 1 and 2, wherein the metal coating comprises at least two metal layers.

[0087] Embodiment 4: The battery assembly according to Embodiment 3, wherein the first metal layer of the at least two metal layers comprises at least one of copper or nickel.

[0088] Embodiment 5: The battery assembly according to Embodiment 4, wherein the second metal layer of the at least two metal layers comprises an alloy.

[0089] Embodiment 6: The battery assembly according to Embodiment 5, wherein the second metal layer includes at least one of a cobalt-phosphorus alloy or a nickel-cobalt alloy.

[0090] Embodiment 7: The battery assembly according to any one of Embodiments 1 to 6, wherein the polymer base layer has a thickness of about 100 μm to about 500 μm.

[0091] Embodiment 8: The battery assembly according to any one of Embodiments 1 to 7, wherein the thickness of the metal coating is about 2 μm to about 100 μm.

[0092] Embodiment 9: The battery assembly according to any one of Embodiments 1 to 8, wherein the polymer base layer comprises a polymer formed from at least one of acrylonitrile, butadiene, or styrene.

[0093] Embodiment 10: The battery assembly according to Embodiment 9, wherein the polymer base layer further comprises at least one of polycarbonate and glass fiber.

[0094] Embodiment 11: The battery assembly of any of Embodiments 1 to 10, wherein the battery housing member defines a recess sized to at least partially surround the battery.

[0095] Embodiment 12: A battery component according to any one of Embodiments 1 to 11, wherein 1) the metal coating is a first metal coating and the surface is a first surface of a polymer base layer, and 2) a second metal coating covers at least a portion of a second surface of the polymer base layer disposed opposite to the first surface.

[0096] Embodiment 13: The battery assembly according to any one of Embodiments 1 to 12, wherein the battery assembly further comprises a battery positioned adjacent to the battery housing member.

[0097] Embodiment 14: A battery assembly according to Embodiment 13, wherein the battery is at least partially surrounded by a battery housing member.

[0098] Embodiment 15: The battery assembly according to any one of Embodiments 1 to 14, wherein a surface of the polymer base layer includes one or more curved portions.

[0099] Embodiment 16: An electronic device comprising a battery and a battery housing member that fixes the battery, the battery housing member comprising 1) a polymer base layer and 2) a metal coating that covers at least a portion of a surface of the polymer base layer.

[0100] Embodiment 17: A method comprising: 1) providing a polymer substrate sized to abut a battery in an electronic device; 2) etching a surface of the polymer substrate; and 3) depositing a metal coating over at least a portion of the surface of the polymer substrate.

[0101] Embodiment 18: The method of Embodiment 17, wherein the method further comprises molding the polymer base layer such that a surface of the polymer base layer comprises one or more bends.

[0102] Embodiment 19: A method according to any one of Embodiments 17 and 18, wherein depositing the metal coating comprises: 1) depositing a first metal layer over the etched surface of the polymer base layer; and 2) depositing a second metal layer over the first metal layer, the second metal layer comprising an alloy.

[0103] Embodiment 20: The method according to Embodiment 19, wherein the second metal layer includes at least one of a cobalt-phosphorus alloy or a nickel-cobalt alloy.

[0104] Embodiments of the present disclosure may include various types of artificial reality systems or be implemented in combination with various types of artificial reality systems. Artificial reality is a form of reality that has been adjusted in some way before being presented to a user, which may include, for example, virtual reality, augmented reality, mixed reality, hybrid reality, or some combination and / or derivative thereof. Artificial reality content may include computer-generated content entirely or computer-generated content combined with captured (e.g., real-world) content. Artificial reality content may include video, audio, tactile feedback, or some combination thereof, any of which may be presented in a single channel or in multiple channels (such as, stereoscopic video that produces a three-dimensional 3D effect to the audience). In addition, in some embodiments, artificial reality may also be associated with applications, products, accessories, services, or some combination thereof that are used, for example, to create content in artificial reality and / or otherwise used in artificial reality (e.g., to perform activities therein).

[0105] Artificial reality systems can be implemented in a variety of different form factors and configurations. Some artificial reality systems can be designed to work without a near-eye display (NED). Other artificial reality systems can include an NED that also provides a view of the real world (such as, for example, Figure 8 visibility of an augmented reality system 1100 in an image, or visually immersing a user in an artificial reality (such as, for example, Fig.12 1200 in the virtual reality system 1200). While some artificial reality devices may be self-contained systems, other artificial reality devices may communicate and / or coordinate with external devices to provide an artificial reality experience to a user. Examples of such external devices include handheld controllers, mobile devices, desktop computers, devices worn by a user, devices worn by one or more other users, and / or any other suitable external system.

[0106] Steering Fig.11, the augmented reality system 1100 may include an eyewear device 1102 having a frame 1110 configured to hold a left display device 1115(A) and a right display device 1115(B) in front of the user's eyes. Display devices 1115(A) and 1115(B) may function together or independently to present an image or group of images to the user. Although the augmented reality system 1100 includes two displays, embodiments of the present disclosure may be implemented in an augmented reality system having a single NED or more than two NEDs.

[0107] In some embodiments, the augmented reality system 1100 may include one or more sensors, such as sensor 1140. Sensor 1140 may generate a measurement signal in response to the movement of the augmented reality system 1100, and the sensor may be located on substantially any portion of the frame 1110. Sensor 1140 may represent one or more of a variety of different sensing mechanisms, such as a position sensor, an inertial measurement unit (IMU), a depth camera assembly, a structured light emitter and / or detector, or any combination thereof. In some embodiments, the augmented reality system 1100 may or may not include sensor 1140 or may include more than one sensor. In embodiments where sensor 1140 includes an IMU, the IMU may generate calibration data based on the measurement signal from sensor 1140. Examples of sensor 1140 may include, but are not limited to, accelerometers, gyroscopes, magnetometers, other suitable types of sensors that detect movement, sensors for error correction of the IMU, or some combination thereof.

[0108] In some examples, the augmented reality system 1100 may also include a microphone array having a plurality of acoustic transducers 1120(A)-1120(J), collectively referred to as acoustic transducers 1120. Acoustic transducers 1120 may represent transducers that detect changes in air pressure caused by sound waves. Each acoustic transducer 1120 may be configured to detect sound and convert the detected sound into an electronic format (e.g., analog or digital format). Fig.11 The microphone array in can include, for example, ten acoustic transducers: acoustic transducers 1120(A) and 1120(B), which can be designed to be placed in the user's respective ears; acoustic transducers 1120(C), 1120(D), 1120(E), 1120(F), 1120(G) and 1120(H), which can be positioned at different locations on the frame 1110; and / or acoustic transducers 1120(I) and 1120(J), which can be positioned on the respective neckbands 1105.

[0109] In some embodiments, one or more of the acoustic transducers 1120(A)-(J) can be used as an output transducer (e.g., a speaker). For example, the acoustic transducers 1120(A) and / or 1120(B) can be earbuds or any other suitable type of earbuds or speakers.

[0110] The configuration of the acoustic transducers 1120 of the microphone array may vary. Fig.11 110, but the number of acoustic transducers 1120 may be greater or less than ten. In some embodiments, the use of a greater number of acoustic transducers 1120 may increase the amount of audio information collected and / or the sensitivity and accuracy of the audio information. Conversely, the use of a lower number of acoustic transducers 1120 may reduce the computing power required by the associated controller 1150 to process the collected audio information. In addition, the position of each acoustic transducer 1120 of the microphone array may vary. For example, the position of the acoustic transducer 1120 may include a defined position on the user, a defined coordinate on the frame 1110, an orientation associated with each acoustic transducer 1120, or some combination thereof.

[0111] The acoustic transducers 1120(A) and 1120(B) can be positioned on different parts of the user's ear, such as behind the pinna, behind the tragus, and / or in the auricle or fossa. Alternatively, in addition to the acoustic transducer 1120 in the ear canal, there can be additional acoustic transducers 1120 on or around the ear. Positioning the acoustic transducers 1120 adjacent to the user's ear canal can enable the microphone array to collect information about how sound reaches the ear canal. By positioning at least two of the acoustic transducers 1120 on either side of the user's head (e.g., as binaural microphones), the augmented reality device 1100 can simulate binaural hearing and capture a 3D stereo sound field around the user's head. In some embodiments, the acoustic transducers 1120(A) and 1120(B) may be connected to the augmented reality system 1100 via a wired connection 1130, and in other embodiments, the acoustic transducers 1120(A) and 1120(B) may be connected to the augmented reality system 1100 via a wireless connection (e.g., a Bluetooth connection). In other embodiments, the acoustic transducers 1120(A) and 1120(B) may not be used in conjunction with the augmented reality system 1100 at all.

[0112] The acoustic transducers 1120 on the frame 1110 can be positioned in a variety of different ways, including along the length of the temples, across the bridge, above or below the display devices 1115(A) and 1115(B), or some combination thereof. The acoustic transducers 1120 can be oriented so that the microphone array can detect sound in a wide range of directions around the user wearing the augmented reality system 1100. In some embodiments, an optimization process can be performed during the manufacture of the augmented reality system 1100 to determine the relative positioning of each acoustic transducer 1120 in the microphone array.

[0113] In some examples, the augmented reality system 1100 can include or be connected to an external device (e.g., a paired device), such as a neckband 1105. Neckband 1105 generally represents any type or form of paired device. Therefore, the following discussion about neckband 1105 is also applicable to various other paired devices, such as charging boxes, smart watches, smart phones, wristbands, other wearable devices, handheld controllers, tablet computers, laptop computers, other external computing devices, etc.

[0114] As shown, the neckband 1105 can be coupled to the eyeglass device 1102 via one or more connectors. The connectors can be wired or wireless and can include electrical and / or non-electrical (e.g., structural) components. In some cases, the eyeglass device 1102 and the neckband 1105 can operate independently without any wired or wireless connection between them. Although Fig.11 Components of the eyeglass device 1102 and neckband 1105 are shown at exemplary locations on the eyeglass device 1102 and neckband 1105, but the components may be positioned in other locations and / or distributed differently on the eyeglass device 1102 and / or neckband 1105. In some embodiments, components of the eyeglass device 1102 and neckband 1105 may be located on one or more additional peripheral devices that are paired with the eyeglass device 1102, neckband 1105, or some combination thereof.

[0115] Pairing an external device (such as a neckband 1105) with an augmented reality eyewear device can enable the eyewear device to achieve the size specifications of a pair of glasses while still providing sufficient battery and computing power for expanded capabilities. Some or all of the battery power, computing resources, and / or additional features of the augmented reality system 1100 can be provided by a paired device or shared between a paired device and the eyewear device, thereby reducing the weight, heat distribution, and size specifications of the overall eyewear device while still maintaining the desired functionality. For example, the neckband 1105 can allow components that were originally included on the eyewear device to be included in the neckband 1105 because the user can bear more weight on their shoulders than on their heads. The neckband 1105 can also have a larger surface area through which heat is diffused and dispersed to the surrounding environment. Therefore, the neckband 1105 can allow for a larger battery and computing capacity than may be available on a standalone eyewear device. Because the weight carried in the neckband 1105 can be less intrusive to the user than the weight carried in the eyeglass device 1102, the user can tolerate wearing the lighter eyeglass device and carrying or wearing the paired device for longer periods of time than the user can tolerate wearing a heavy standalone eyeglass device, thereby enabling the user to more fully integrate the artificial reality environment into their daily activities.

[0116] The neckband 1105 can be communicatively coupled to the eyewear device 1102 and / or other devices. These other devices can provide certain functions (e.g., tracking, localizing, depth mapping, processing, storage, etc.) to the augmented reality system 1100. Fig.11 In an embodiment, the neckband 1105 may include two acoustic transducers (e.g., 1120(I) and 1120(J)) that are part of a microphone array (or may form their own microphone subarray). The neckband 1105 may also include a controller 1125 and a power supply 1135.

[0117] The acoustic transducers 1120(I) and 1120(J) of the neckband 1105 may be configured to detect sound and convert the detected sound into an electronic format (analog or digital). Fig.11In an embodiment of the present invention, the acoustic transducers 1120(I) and 1120(J) can be positioned on the neckband 1105, thereby increasing the distance between the neckband acoustic transducers 1120(I) and 1120(J) and other acoustic transducers 1120 positioned on the eyeglass device 1102. In some cases, increasing the distance between the acoustic transducers 1120 of the microphone array can improve the accuracy of the beamforming performed via the microphone array. For example, if the acoustic transducers 1120(C) and 1120(D) detect a sound, and the distance between the acoustic transducers 1120(C) and 1120(D) is greater than, for example, the distance between the acoustic transducers 1120(D) and 1120(E), the determined source location of the detected sound can be more accurate than the sound detected by the acoustic transducers 1120(D) and 1120(E).

[0118] The controller 1125 of the neckband 1105 can process information generated by sensors on the neckband 1105 and / or the augmented reality system 1100. For example, the controller 1125 can process information from the microphone array describing the sound detected by the microphone array. For each detected sound, the controller 1125 can perform a direction of arrival (direction-of-arrival, DOA) estimation to estimate the direction in which the detected sound arrives at the microphone array. When the microphone array detects a sound, the controller 1125 can fill the audio data set with this information. In an embodiment in which the augmented reality system 1100 includes an inertial measurement unit, the controller 1125 can calculate all inertial and spatial calculations based on the IMU located on the glasses device 1102. The connector can transmit information between the augmented reality system 1100 and the neckband 1105 and between the augmented reality system 1100 and the controller 1125. The information can be in the form of optical data, electrical data, wireless data, or any other transmittable data form. Moving the processing of information generated by the augmented reality system 1100 to the neck strap 1105 can reduce the weight and heat of the eyewear device 1102, making it more comfortable for the user.

[0119] The power source 1135 in the neckband 1105 can provide power to the eyeglass device 1102 and / or the neckband 1105. The power source 1135 can include, but is not limited to, lithium-ion batteries, lithium polymer batteries, lithium primary batteries, alkaline batteries, or any other form of power storage. In some cases, the power source 1135 can be a wired power source. Including the power source 1135 on the neckband 1105 instead of the eyeglass device 1102 can help better distribute the weight and heat generated by the power source 1135.

[0120] As described, some artificial reality systems can essentially replace one or more of the user's sensory perceptions of the real world with a virtual experience, rather than mixing the artificial reality with the actual reality. An example of this type of system is a head mounted display system, such as Fig.12 1200, which covers most or all of the user's field of view. The virtual reality system 1200 may include a front rigid body 1202 and a band 1204 shaped to fit around the user's head. The virtual reality system 1200 may also include output audio transducers 1206 (A) and 1206 (B). In addition, although in Fig.12 Not shown, but front rigid body 1202 may include one or more electronic components, including one or more electronic displays, one or more inertial measurement units (IMUs), one or more tracking transmitters or detectors, and / or any other suitable device or system for creating an artificial reality experience.

[0121] Artificial reality systems may include various types of visual feedback mechanisms. For example, the display devices in the augmented reality system 1100 and / or the virtual reality system 1200 may include one or more liquid crystal displays (LCD), light emitting diode (LED) displays, micro LED displays, organic LED (OLED) displays, digital light project (DLP) micro displays, liquid crystal on silicon (LCoS) micro displays and / or any other suitable type of display screen. These artificial reality systems may include a single display screen for both eyes or a display screen may be provided for each eye, which may allow additional flexibility for zoom adjustment or for correcting the user's refractive error. Some of these artificial reality systems may also include an optical subsystem having one or more lenses (e.g., concave or convex lenses, Fresnel lenses, adjustable liquid lenses, etc.) through which a user can view a display screen. These optical subsystems can be used for a variety of purposes, including collimating (e.g., making an object appear to be at a greater distance than it is physically at), magnifying (e.g., making an object appear larger than its actual size), and / or delivering (e.g., to a viewer's eye) light. These optical subsystems can be used in non-pupil-forming architectures (e.g., a single-lens configuration, which directly collimates light but results in so-called pincushion distortion) and / or pupil-forming architectures (e.g., a multi-lens configuration, which produces so-called barrel distortion to counteract pincushion distortion).

[0122] In addition to or in lieu of using a display screen, some of the artificial reality systems described herein may include one or more projection systems. For example, a display device in the augmented reality system 1100 and / or the virtual reality system 1200 may include a micro-LED projector that projects light into the display device (using, for example, a waveguide), such as a transparent combiner lens that allows ambient light to pass through. The display device may refract the projected light into the user's pupil, and may enable the user to view both the artificial reality content and the real world simultaneously. The display device may use any of a variety of different optical components to achieve this, including waveguide components (e.g., holographic, planar, diffractive, polarized, and / or reflective waveguide elements), light manipulation surfaces and elements (such as diffractive, reflective, and refractive elements and gratings), coupling elements, and the like. The artificial reality system may also be configured with any other suitable type or form of image projection system, such as a retinal projector for a virtual retinal display.

[0123] The artificial reality systems described herein may also include various types of computer vision components and subsystems. For example, the augmented reality system 1100 and / or the virtual reality system 1200 may include one or more optical sensors, such as two-dimensional (2D) or 3D cameras, structured light emitters and detectors, time-of-flight depth sensors, single-beam or scanning laser rangefinders, 3D LiDAR sensors, and / or any other suitable type or form of optical sensor. The artificial reality system may process data from one or more of these sensors to identify the user's location, to map the real world, to provide the user with context about the real world environment, and / or to perform various other functions.

[0124] The artificial reality system described herein may also include one or more input and / or output audio transducers. The output audio transducer may include a voice coil speaker, a ribbon speaker, an electrostatic speaker, a piezoelectric speaker, a bone conduction transducer, a cartilage conduction transducer, an ear tragus vibration transducer, and / or any other suitable type or form of audio transducer. Similarly, the input audio transducer may include a condenser microphone, a dynamic microphone, a ribbon microphone, and / or any other type or form of input transducer. In some embodiments, a single transducer may be used for both audio input and audio output.

[0125] In some embodiments, the artificial reality system described herein may also include a tactile (i.e., haptic) feedback system that can be incorporated into headwear, gloves, tights, handheld controllers, environmental equipment (e.g., chairs, floor mats, etc.), and / or any other type of device or system. The tactile feedback system can provide various types of skin feedback, including vibration, force, traction, texture, and / or temperature. The tactile feedback system can also provide various types of kinesthetic feedback, such as motion and compliance. Tactile feedback can be implemented using motors, piezoelectric actuators, fluid systems, and / or various other types of feedback mechanisms. The tactile feedback system can be implemented independently of other artificial reality devices, within other artificial reality devices, and / or in combination with other artificial reality devices.

[0126] By providing tactile, auditory content, and / or visual content, artificial reality systems can create complete virtual experiences or enhance the user's real-world experience in various contexts and environments. For example, artificial reality systems can help or expand a user's perception, memory, or cognition in a specific environment. Some systems can enhance the user's interaction with other people in the real world, or can achieve a more immersive interaction with other people in the virtual world. Artificial reality systems can also be used for educational purposes (e.g., for teaching or training in schools, hospitals, government organizations, military organizations, commercial enterprises, etc.), entertainment purposes (e.g., for playing video games, listening to music, watching video content, etc.), and / or for accessibility purposes (e.g., as hearing aids, visual aids, etc.). The embodiments disclosed herein can implement or enhance the user's artificial reality experience in one or more contexts and environments and / or other contexts and environments in these contexts and environments.

[0127] As mentioned above, the computing devices and systems described and / or illustrated herein broadly represent any type or form of computing devices or systems capable of executing computer-readable instructions, such as those contained in the modules described herein. In their most basic configuration, these computing devices can each include at least one storage device and at least one physical processor.

[0128] In some examples, the term "storage device" generally refers to any type or form of volatile or non-volatile storage device or medium capable of storing data and / or computer-readable instructions. In one example, a storage device can store, load and / or maintain one or more modules described herein. Examples of memory devices include, but are not limited to, random access memory (RAM), read-only memory (ROM), flash memory, hard disk drive (HDD), solid-state drive (SSD), optical drive, cache, one or more variants or combinations thereof, or any other suitable storage memory.

[0129] In some examples, the term "physical processor" generally refers to any type or form of hardware-implemented processing unit capable of interpreting and / or executing computer-readable instructions. In one example, a physical processor can access and / or modify one or more modules stored in the above-mentioned storage device. Examples of physical processors include, but are not limited to, a microprocessor, a microcontroller, a central processing unit (CPU), a field programmable gate array (FGA) implementing a soft-core processor, an application-specific integrated circuit (ASIC), a portion of one or more ASICs, a variant or combination of one or more ASICs, or any other suitable physical processor.

[0130] Although shown as separate elements, the modules described and / or shown herein can represent the parts of single modules or applications. In addition, in certain embodiments, one or more of these modules can represent one or more software applications or programs, which, when executed by a computing device, can enable the computing device to perform one or more tasks. For example, one or more modules described and / or shown herein can represent storage and be configured to run on one or more computing devices or systems described and / or shown herein. One or more of these modules can also represent all or part of one or more special-purpose computers configured to perform one or more tasks.

[0131] In addition, one or more modules described herein may convert data, physical devices, and / or representations of physical devices from one form to another. For example, one or more modules described herein may receive a biopotential signal to be converted, convert the biopotential signal to data indicative of a vital sign of a user, output the result of the conversion, use the result of the conversion to provide information to the user, and store the result of the conversion. Additionally or alternatively, one or more modules described herein may convert a processor, volatile memory, non-volatile memory, and / or any other part of a physical computing device from one form to another by executing on a computing device, storing data on a computing device, and / or otherwise interacting with a computing device.

[0132] In some embodiments, the term "computer-readable medium" generally refers to any form of device, carrier, or medium capable of storing or carrying computer-readable instructions. Examples of computer-readable media include, but are not limited to, transmission-type media such as carrier waves, and non-transitory media such as magnetic storage media (e.g., hard drives, tape drives, and floppy disks), optical storage media (e.g., compact disks (CDs), digital video disks (DVDs), and Blu-ray disks), electronic storage media (e.g., solid-state drives and flash memory media), and other distribution systems.

[0133] The process parameters and order of steps described and / or illustrated herein are provided as examples only and may be changed as desired. For example, although the steps illustrated and / or described herein may be illustrated or discussed in a particular order, the steps do not necessarily need to be performed in the order illustrated or discussed. The various exemplary methods described and / or illustrated herein may also omit one or more of the steps described or illustrated herein, or include additional steps in addition to the disclosed steps.

[0134] The foregoing description has been provided to enable others skilled in the art to best utilize the various aspects of the exemplary embodiments disclosed herein. This exemplary description is not intended to be exhaustive or limited to any precise form disclosed. Many modifications and variations are possible without departing from the spirit and scope of the present disclosure. The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The attached claims and their equivalents should be referenced when determining the scope of the present disclosure.

[0135] Unless otherwise noted, the terms "connected to" and "coupled to" (and their derivatives) as used in the specification and claims should be interpreted as allowing both direct and indirect (i.e., via other elements or components) connections. In addition, the terms "a" or "an" as used in the specification and claims should be interpreted as meaning "at least one." Finally, for ease of use, the terms "including" and "having" (and their derivatives) as used in the specification and claims may be interchangeable with the word "comprising" and have the same meaning. Systems and methods for charging electronic devices

[0136] The present disclosure generally relates to improved techniques for charging batteries of electronic devices (such as smart devices, smart glasses, head-mounted displays, etc.) from an additional battery source. In one example, an additional battery source (such as a charging box for an electronic device) may include an adjustable boost circuit that increases the voltage level of the additional battery source to the exact voltage required to effectively charge the battery of the electronic device. Specifically, the disclosed system can utilize a communication method that transmits the voltage level of a battery in an electronic device to a charging device, which can then determine the appropriate voltage level for most effectively charging the battery of the electronic device. By doing so, the disclosed system can improve the charging efficiency of the electronic device and reduce battery capacity requirements.

[0137] In one example, a method for charging an electronic device may include receiving battery status information from the electronic device (via, for example, firmware of the device), the battery status information identifying a voltage level of a battery of the electronic device. The method may also include determining a charging mode for charging the electronic device from an additional battery source (e.g., a housing battery) based on the battery status information. Examples of such charging modes include a boost mode that may increase the voltage level of the additional battery source before charging and a bypass mode that may not increase the voltage level of the additional battery source before charging. The method may then include charging the electronic device by the additional battery source using the determined charging mode.

[0138] In some embodiments, a voltage regulator associated with an additional battery source and / or an electronic device can be selectively activated to operate in bypass mode and / or boost mode to improve charging efficiency. In some examples, a charging chipset can be used to implement selective activation of bypass and / or boost modes. By doing so, the disclosed method can provide dynamic feedback between an additional battery source and an electronic device to achieve control and / or regulation of the headroom across each device. In some embodiments, a firmware control method (e.g., a firmware control loop) can be used to monitor the voltage value of an electronic device. In addition, these firmware control methods can include monitoring the battery voltage value of an electronic device over time and / or at fixed intervals and / or at variable intervals.

[0139] Example Implementation

[0140] Embodiment 1: A method for charging an electronic device, the method comprising: receiving battery status information from the electronic device, the battery status information identifying a voltage level of a battery of the electronic device; determining a charging mode for charging the electronic device from an additional battery source based on the battery status information, the charging mode comprising at least one of a boost mode for boosting the voltage level of the additional battery source before charging or a bypass mode for not boosting the voltage level of the additional battery source before charging; and charging the electronic device by the additional battery source using the determined charging mode.

[0141] System and method for improving battery charging

[0142] The present disclosure generally relates to improved techniques for battery charging that utilize a combination of hardware and firmware methods to protect the battery from charging current exposure. In one example, the disclosed system may include hardware over-protection circuits (e.g., fuses, circuit breakers, power switches, diodes, relays, etc.) that reduce safety risks associated with the battery (e.g., temperature exposure, heat exposure, charging current exposure, etc.). As described herein, the disclosed techniques can both improve the charging efficiency of the battery and protect the battery from vulnerability.

[0143] In one example, a method for improving battery charging may include receiving battery status information from an overcurrent protection circuit, the battery status information identifying a charging current level of the battery. The method may also include determining a charging scheme for charging the battery based on the battery status. In some embodiments, the charging scheme may include identifying the temperature level of the battery via a temperature sensor integrated in the overcurrent protection circuit. In addition, when the identified temperature level reaches a temperature threshold, the charging scheme may compare the identified charging current level with a charging current threshold. The charging scheme may also include activating an overcurrent protection circuit to disable charging of the battery when the identified charging current level exceeds the charging current threshold and the identified temperature level is below the temperature threshold. For example, the charging scheme may limit and / or disable charging of the battery in response to the identified temperature reaching a temperature value including <0°C and 0°C to 10°C. In some cases, charging may remain disabled until the identified temperature level returns to a value above the temperature threshold.

[0144] In some embodiments, the systems described herein may include additional components integrated into the overcurrent protection circuit to protect the battery. For example, the overcurrent protection circuit may include, but is not limited to, current sensors, amplifiers, temperature sensors, comparison circuits, logic units, programmable logic devices, etc. In some embodiments, these additional components may be fully integrated into an integrated circuit designed to manage the overcurrent protection circuit.

[0145] Example Implementation

[0146] Embodiment 1: A method for charging a battery, the method comprising: receiving battery status information from a circuit, the battery status information identifying a charging current level of the battery; determining a charging scheme for charging the battery based on the battery status information, the charging scheme comprising identifying a temperature level of the battery via a sensor; comparing the identified charging current level with a charging current threshold associated with a temperature threshold; and activating a circuit to disable charging of the battery when the charging current level exceeds the charging current threshold and the identified temperature level is below the temperature threshold.

[0147] System and method for improving battery derating

[0148] The present disclosure generally relates to improved techniques for battery derating, including utilizing a firmware system via a combined hardware approach to predict when a battery is exposed to high temperatures. In one example, the method may include a tiered system that limits battery charging and / or derates battery capacity. In another example, the method may include using a gas pressure gauge to generate a thermal map indicating the duration a battery spends at different exposure level values. By doing so, the disclosed system may include the ability to increase the overall life of the battery and / or maximize the battery capacity by preventing future exposure.

[0149] In one example, a method for improving battery derating may include dynamically managing battery capacity based on exposure to high temperature and / or voltage. The method may also include continuously monitoring the exposure level value (such as temperature and / or voltage) of the battery via a gas pressure gauge, which generates a thermal map indicating the duration of time the battery spends at different exposure level values. In some embodiments, using a thermal map may include calculating a risk value by a formula (such as a weighted sum formula) applied to the exposure level values ​​in the thermal map. In other embodiments, the method may include comparing the calculated risk value with a predetermined threshold to determine the exposure level value of the battery. In a further embodiment, the method may include a firmware system configured to access the thermal map via an integrated circuit to enable dynamic communication between the gas pressure gauge and the firmware system. In addition, the method may include a grading system for implementing battery capacity limitations based on the determined exposure level values.

[0150] In some embodiments, the predetermined thresholds may correspond to different exposure levels of the battery. In other embodiments, the grading system may include methods for limiting charging and / or de-rating the battery capacity, such as a first threshold that triggers a warning, a second threshold that triggers a first limitation on the battery capacity, and a third threshold that triggers a second limitation.

[0151] Example Implementation

[0152] Embodiment 1: A method, comprising: continuously monitoring the exposure level value of a battery via a gas pressure gauge, the gas pressure gauge generating a heat map indicating the duration spent at different exposure level values; calculating a risk value based on the exposure level values ​​in the heat map; comparing the calculated risk value with a predetermined threshold to determine the exposure level value of the battery; and implementing a grading system for battery capacity limitation based on the determined exposure level value.

[0153] Systems and methods for improving battery packs

[0154] The present disclosure generally relates to improved techniques for battery packaging utilizing a battery cell design (e.g., a pouch cell design, a hard shell cell design, etc.) with shared packaging materials, which results in more efficient packaging of battery cells having two or more battery cell bodies connected in series and / or in parallel. In one example, the shared packaging material may include a bottom bag layer shared between two or more battery cell bodies. The shared bottom bag layer may form an outer shell to facilitate connecting the battery cells side by side in a plane. In a further example, the battery cell design may include a flexible and / or length-adjustable side seal area. The flexible design of the side seal area may enable flexible dimensional specifications for battery cell design, including shapes such as cubes, curved, shaped, chamfered, etc. In other examples, the battery cell design may include flexible cell sizes and / or cell dimensions, wherein the battery cell bodies may be the same size and / or different sizes (e.g., the length, width, and / or thickness of the cell body). In a further example, the battery cell design may include terminal labels that may be on the same side of the battery cell and / or on opposite sides of the battery cell. In addition, the terminal tags can be connected in series or parallel to battery cells that share a platform, including battery cells that may not share a platform.

[0155] In some embodiments, the shared packaging material may also include an intermediate layer shared between two or more battery cells, where the battery cells may be stacked in the thickness direction (e.g., stacked on the top and bottom). In further embodiments, the shared intermediate layer may be a thin layer of polymer material (such as polypropylene) and / or multiple layers of laminate material (such as aluminum bag film). In addition, the shared intermediate layer may include shared side seals and top seals that can reduce inactive weight and volume in the battery pack.

[0156] As described herein, the disclosed designs for battery cell designs can include fewer inactive parts and reduced material weight and / or volume ratios, which can increase the volumetric energy density and weight energy density of the battery cell. Further, the battery cell design can be assembled via methods including heat sealing, laser welding, mechanical cramping, etc.

[0157] Example Implementation

[0158] Embodiment 1: A shared packaging material for a battery having at least two battery cell bodies connected in series or in parallel, the shared packaging comprising: a bottom pouch layer, which is shared between at least two battery cell bodies placed side by side with each other, and the shared bottom pouch layer includes a flexible side seal region; and an intermediate layer, which is shared between at least two battery cell bodies stacked in a thickness direction, and the shared intermediate layer includes a thin layer of a polymer material.

[0159] Embodiment 2: The shared packaging material according to embodiment 1, wherein the length of the flexible side sealing area between at least two battery cells is adjustable.

Claims

1. A battery assembly, comprising: A battery housing member sized to secure a battery in an electronic device, the battery housing member comprising: a polymer base layer; and A metal coating covers at least a portion of a surface of the polymer-based layer.

2. The battery assembly according to claim 1, wherein: The surface of the polymer-based layer includes an etched surface.

3. The battery assembly according to claim 1, wherein: The metal coating includes at least two metal layers.

4. The battery assembly according to claim 3, wherein: A first metal layer of the at least two metal layers includes at least one of copper or nickel.

5. The battery assembly according to claim 4, wherein: A second metal layer of the at least two metal layers includes an alloy.

6. The battery assembly according to claim 5, wherein: The second metal layer includes at least one of a cobalt-phosphorus alloy or a nickel-cobalt alloy.

7. The battery assembly according to claim 1, wherein: The polymer base layer has a thickness of about 100 μm to about 500 μm.

8. The battery assembly according to claim 1, wherein: The thickness of the metal coating is about 2 μm to about 100 μm.

9. The battery assembly according to claim 1, wherein: The polymer base layer includes a polymer formed from at least one of acrylonitrile, butadiene, or styrene.

10. The battery assembly according to claim 9, wherein: The polymer substrate further includes at least one of polycarbonate and glass fiber.

11. The battery assembly according to claim 1, wherein: The battery housing member defines a recess sized to at least partially surround the battery.

12. The battery assembly according to claim 1, wherein: The metal coating is a first metal coating, and the surface is a first surface of a polymer-based layer; and The second metal coating covers at least a portion of a second surface of the polymer-based layer disposed opposite the first surface.

13. The battery assembly according to claim 1, wherein: The battery assembly also includes a battery positioned adjacent to the battery housing member.

14. The battery assembly according to claim 13, wherein: The battery is at least partially surrounded by the battery housing member.

15. The battery assembly according to claim 1, wherein: The surface of the polymer-based layer includes one or more curvatures.

16. An electronic device, comprising: Battery; as well as A battery housing member, the battery housing member fixing the battery, the battery housing member comprising: polymer base layer; as well as A metal coating covers at least a portion of a surface of the polymer-based layer.

17. A method comprising: providing a polymer substrate sized to abut a battery in an electronic device; etching the surface of the polymer substrate; as well as A metal coating is deposited over at least a portion of the surface of the polymer-based layer.

18. The method according to claim 17, wherein: The method also includes molding the polymeric base layer such that the surface of the polymeric base layer includes one or more curvatures.

19. The method according to claim 17, wherein: Depositing the metal coating comprises: depositing a first metal layer over the etched surface of the polymer-based layer; and A second metal layer is deposited over the first metal layer, the second metal layer comprising an alloy.

20. The method according to claim 19, wherein: The second metal layer includes at least one of a cobalt-phosphorus alloy or a nickel-cobalt alloy.

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