Electrical device

Abstract

An electrical device includes a housing, a printed circuit board disposed in the housing, and a plastic molded on at least a portion of the printed circuit board; the printed circuit board includes: an electrical component mounted on the printed circuit board; and a plurality of openings, wherein the plurality of openings are limited in the printed circuit board; wherein the plastic covers at least some of the electrical components on the printed circuit board, and the plurality of openings remain exposed.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] The present invention claims priority to U.S. Provisional Patent Application No. 63 / 425,739 filed on November 16, 2022, the entire contents of which are hereby incorporated by reference into this application. Technical Field

[0003] The utility model relates to an electrical device, and more particularly to an electrical device such as a battery pack. Background Art

[0004] An electrical device such as a battery pack includes a printed circuit board and at least one battery cell. The printed circuit board includes electrical components that need to be protected from debris that may enter the battery pack. The battery cell is disposed in an interior space of the battery pack. The battery pack may further include an inner housing that securely holds the battery cell within the battery pack. Utility Model Content

[0005] The utility model provides an electrical device in one aspect, which comprises a shell, a printed circuit board placed in the shell, and plastic molded on at least a part of the printed circuit board.

[0006] In another aspect, the utility model provides an electrical device, which comprises a housing, at least one battery cell placed in the housing, and plastic molded on at least a portion of the at least one battery cell.

[0007] In some embodiments, the at least one battery cell includes a plurality of battery cells, the plurality of battery cells including soft-pack batteries, each soft-pack battery including a body and at least one terminal tab, the at least one terminal tab extending from the body, and a majority of the body of each soft-pack battery is covered by the plastic.

[0008] In some embodiments, the plastic is a first plastic, and further includes a second plastic molded on at least a portion of the soft pack battery to cover the first plastic and form a battery core.

[0009] In some embodiments, the electrical device further includes: a first printed circuit board, the first printed circuit board coupled to the second plastic through a plurality of tabs formed thereon; a second printed circuit board, the second printed circuit board mounted on the first printed circuit board; and a third plastic, the third plastic molded on at least a portion of the second printed circuit board.

[0010] In some embodiments, the electrical device further includes: a terminal partition, which is mounted on the second printed circuit board; and a fourth plastic, which is molded on at least a portion of the terminal partition and covers at least a portion of the third plastic.

[0011] The utility model provides a method for manufacturing an electrical device in another aspect. The method includes installing a printed circuit board in a cavity of a mold and injecting molten plastic into the cavity to form a plastic body. The plastic body is molded on at least a portion of the printed circuit board. The method further includes removing the printed circuit board with the plastic from the cavity. The plastic is injected into the cavity at a pressure of at least 50 psi. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a three-dimensional diagram of a battery pack.

[0013] Figure 2A is placed Figure 1 A top perspective view of the various components within a battery pack.

[0014] Figure 2B yes Figure 2A A bottom perspective view of the components.

[0015] Figure 2C yes Figure 2A A top view of the component.

[0016] Figure 2D yes Figure 2A Bottom view of the component.

[0017] Figure 2E yes Figure 2A An enlarged view of the components.

[0018] Figure 3A is a three-dimensional image of a circuit board covered by a plastic body.

[0019] Figure 3B yes Figure 3A A top view of the circuit board.

[0020] Figure 3C yes Figure 3A Bottom view of the circuit board.

[0021] Figure 4A This is a top view of the circuit board without the plastic.

[0022] Figure 4B yes Figure 4A Bottom view of the circuit board.

[0023] Figure 5 This is a three-dimensional diagram of the terminal partition.

[0024] Figure 6 According to another specific embodiment of the utility model, Figure 1 A three-dimensional diagram of the various components within a battery pack.

[0025] Fig. 7A yes Figure 6 A top view of the device with some of its components removed.

[0026] Figure 7B yes Figure 6 Bottom view of the component.

[0027] Fig. 8A is a perspective view of a USB battery covered by a first plastic body.

[0028] Figure 8B yes Fig. 8A A perspective view of a USB battery covered by a second plastic body.

[0029] Fig. 9A It is a three-dimensional view of a plurality of battery cells covered by a first plastic body.

[0030] Fig. 9B yes Fig. 9A A three-dimensional diagram of multiple battery cells.

[0031] Fig. 9C It is a perspective view of a plurality of battery cells covered by a second plastic body.

[0032] Fig.9D Covered by the outer shell Fig. 9A A three-dimensional diagram of multiple battery cells.

[0033] Fig. 10A is a perspective view of a plurality of battery cells partially covered by a plastic body according to another specific embodiment.

[0034] Fig. 10B yes Fig. 10A A three-dimensional diagram of multiple battery cells.

[0035] Fig.11A is a cross-sectional view of a battery pack according to another specific embodiment.

[0036] Fig. 11B is placed Fig.11A A three-dimensional view of a pair of battery cells within a battery pack.

[0037] Fig. 12A is a cross-sectional view of a battery pack according to another specific embodiment.

[0038] Fig. 12B is placed Fig. 12AA three-dimensional view of multiple battery cells within a battery pack.

[0039] Fig.13A is a cross-sectional view of a battery pack according to another specific embodiment.

[0040] Fig. 13B is placed Fig.13A A three-dimensional view of multiple battery cells within a battery pack.

[0041] Fig.14A is a perspective view of a plurality of battery cells according to another embodiment.

[0042] Fig. 14B FIG. 14 is a top view of the plurality of battery cells.

[0043] Fig.15A is a perspective view of a plurality of battery cells according to another embodiment.

[0044] Fig. 15B yes Fig.15A A cross-sectional view of multiple battery cells.

[0045] Fig.16A is a perspective view of the inner battery housing.

[0046] Fig. 16B yes Fig.16A A partial view of the inner battery casing.

[0047] Fig.17A is placed Fig.16A A three-dimensional view of a first group of battery cells within an inner battery housing.

[0048] Fig. 17B yes Fig.17A A top view of a first group of battery cells.

[0049] Fig.18A is placed Fig.16A A perspective view of a second group of battery cells within an inner battery housing

[0050] Fig.18B yes Fig.18A A top view of a second group of battery cells.

[0051] Fig.19 is a perspective view of a battery pack with portions removed according to another specific embodiment.

[0052] Fig. 20A It is a three-dimensional diagram of a soft-pack battery.

[0053] Fig. 20B yes Fig. 20A Cross-sectional view of a soft-pack battery.

[0054] Fig.21 is placed Fig.19 A three-dimensional image of the battery core within a battery pack.

[0055] Fig. 22 Is installed in Fig.21 A three-dimensional diagram of the various components on the battery core.

[0056] Fig.23 It is a three-dimensional view of the terminal partition covered by the plastic body.

[0057] Fig.24 is a perspective view of a circuit board according to another specific embodiment.

[0058] Before explaining any specific embodiment of the present invention in detail, it is necessary to understand that the present invention is not limited to its application in the configuration and component arrangement described below or shown in the accompanying drawings. The present invention can have other specific embodiments and can be implemented and realized in various ways. In addition, it should be understood that the words and terms used in the present invention are for illustrative purposes only and should not be interpreted as limiting. DETAILED DESCRIPTION

[0059] Figure 1 The battery pack 10 is shown. The battery pack 10 includes a housing 14 formed by a bottom housing 18 and a top housing 22 coupled to the bottom housing 18. The bottom housing 18 is configured to receive and support various internal components of the battery pack 10. The top housing 22 includes an output port 26, which is configured to be received by an electrical device (such as a power tool) so as to couple the battery pack 10 to the electrical device for power supply. The top housing 22 can be fastened to the bottom housing 18 by a plurality of fasteners (not shown). The battery pack 10 also includes a plurality of battery cells (not shown) disposed in the bottom housing 18. The plurality of battery cells are configured to supply power to the electrical device when the battery pack 10 is coupled to the electrical device. Each battery cell includes a positive terminal and a negative terminal. The plurality of battery cells include any number of different nominal voltages (such as 12V, 18V, etc.), and can be configured to have any number of different chemical formulas (such as lithium ion, nickel cadmium, etc.). The battery cell can be cylindrical, soft-pack, prismatic, or similar shapes.

[0060] See also Figures 2A-3C, the battery pack 10 further includes a cell tap assembly 30, a printed circuit board (PCB) 34, and a terminal partition 38, which are placed in the housing 14 of the battery pack 10. The PCB 34 is configured to be placed above the battery cell and includes a plurality of electrical components 42 (shown in dotted lines) mounted on the top and bottom sides of the PCB 34 by an adhesive or other fastening method. The electrical component 42 is configured to control the charging and discharging operations of the battery cell. In addition, the electrical component 42 is configured to monitor the temperature of the battery cell. The top housing 22 is consistent with the shape of the terminal partition 38 so that the output port 26 surrounds the terminal partition 38. The terminal partition 38 includes a terminal housing 39 and a plurality of terminals 40 surrounded by the terminal housing 39. The terminal partition 38 is mounted on the PCB 34 and electrically connected to the PCB 34 to provide power from the battery cell to the electrical device.

[0061] The unit tap assembly 30 includes a plurality of straps 46. Each strap 46 includes a post 50, a tab 54, and a connecting portion 56 configured to connect the post 50 to the tab 54. The post 50 of each strap 46 is configured to extend through a corresponding opening 58 ( Figure 2E-3C ). The tabs 54 are configured to engage corresponding terminals formed on the battery cells. In this way, the cell tap assembly 30 is configured to electrically connect the PCB 34 to a plurality of battery cells.

[0062] Once the electrical components 42 are mounted on the PCB 34, the plastic body 62 is molded on at least a portion of the PCB 34. In some embodiments, the plastic body 62 is formed by low pressure overmolding (LPOM). Embodiments of the present invention contemplate insert molding, overmolding, or any other process of adding liquid plastic to an existing object. During the molding process, the PCB 34 is fixed inside a cavity formed in a mold (not shown). The cavity includes features / contours that form the shape of the plastic body 62. The features / contours of the cavity are specifically designed so that the plastic body 62 can cover a specific area of ​​the PCB 34. The plastic is transported in an injection unit (not shown), which is configured to heat the plastic until it is melted around a heating mechanism. The heating mechanism can heat the plastic at a temperature between 350 and 450 degrees Fahrenheit. The molten plastic is then injected into the cavity of the mold and held in the cavity until the plastic hardens to form the plastic body 62. In some embodiments, the plastic is injected into the cavity at a low pressure of 50psi to 200psi (345kPa to 1379kPa). The PCB 34 is then removed from the cavity of the mold. Plastic materials such as polyamide and polyolefin can be used. In other embodiments, the material may include a heat conductive material to improve the thermal performance of the battery pack 10.

[0063] In other embodiments, PCB34 may be subjected to multi-shot molding to form a plastic body made of at least two plastic materials. During the multi-shot molding process, a first plastic material is injected into a first cavity of a first mold to form a first plastic body covering a portion of PCB34. PCB34 and the first plastic body are then transferred to a second cavity of a second mold. Then, a second plastic material is injected into the second cavity to form a second plastic body. In one embodiment, the second plastic body may completely cover the first plastic body and PCB34. In another embodiment, the second plastic body may cover a portion of the first plastic body. In yet another embodiment, the first plastic body may cover a portion of PCB34. The second plastic body may cover the remainder of PCB34 and the first plastic body. In some embodiments, the second plastic body is made of the same material as the first plastic body. Using multi-shot molding can help phase changes around electrical components 42 that may be hot, thereby reducing the chance of thermal runaway. In this way, plastic body 62 can spread the heat generated by PCB34, so that PCB34 operates at a cool temperature, thereby improving reliability.

[0064] The cavity of the mold is specifically designed so that the PCB 34 is not completely covered by the plastic body 62. Figure 2E 4, the opening 58 remains exposed to the surrounding environment. The posts 50 of each strip 46 can extend through the opening 58 without being interfered by the plastic body 62. The portion of the PCB 34 where the terminal partition 38 is mounted is also not covered by the plastic body 62. The plastic body 62 covers the top and bottom portions of the PCB 34. Specifically, the plastic body 62 covers the area where the electrical components 42 are mounted. In addition, a plurality of electrical components 42a-42e can extend through the plastic body 62.

[0065] The plastic body 62 is coupled to the PCB 34 without the support of an adhesive because the plastic body 62 acts as its own adhesive when coupled to the PCB 34. In addition, the plastic body 62 is configured to cover and protect the electrical components 42 from debris and water that may enter the battery pack 10. In this way, the plastic body 62 acts as a water-resistant barrier that provides ingress protection to prevent debris and water from contacting and damaging the electrical components 42. The plastic body 62 also protects the PCB 34 from corrosion. Accordingly, in some embodiments, the plastic body 62 does not need to cover the PCB 34 with a conformal coating. This improves the time and consistency of manufacturing the battery pack 10. In some embodiments, the manufacturing process of the battery pack 10 no longer needs to include covering the PCB 34 with a conformal coating.

[0066] The areas where the openings 58 are located can be considered common corrosion locations because conformal coatings are manually applied and removed from these areas of the PCB 34. As such, the conformal coating may not properly protect the PCB 34 because the conformal coating may not properly cover the precise geometry of the PCB 34. The plastic body 62 does not require conformal coating because the plastic body 62 is precisely constructed to provide uniform protection. In the illustrated embodiment, the plastic body 62 is intentionally constructed to surround the openings 58, thereby improving ingress protection for the entire PCB 34.

[0067] See also Figure 4A and 4B , which shows another embodiment of a PCB 63. The PCB 63 includes a plurality of electrical components 64 mounted thereon, a plurality of openings 65, and a pair of soldering portions 67 with electrodes 69. In the illustrated embodiment, a plastic body (not shown) is molded over at least a portion of the PCB 63, which allows a portion of the electrical components 64 to be covered. The plurality of openings 65 and the soldering portions 67 remain exposed to the surrounding environment. Molding the plastic body along the soldering portions 67 can cause the electrodes 69 to become dirty and cause soldering problems.

[0068] See also Figure 5 , which shows the terminal partition 70. The terminal partition 70 can be mounted on the PCB 63. In this way, the plastic body is not configured to cover the terminal partition 70. In addition, the plastic body does not cover the area on the PCB 63 where the terminal partition 70 is located.

[0069] See also Figure 6-7B , which shows another specific embodiment of a battery pack 100. The battery pack 100 and Figure 1-3C The battery pack 10 is similar to the battery pack 10; therefore, the same structure will be marked with the same reference numerals plus "100".

[0070] PCB134 is mounted on top of the battery core 190, which is placed in the bottom housing of the battery pack 100. The plastic body 162 partially covers the PCB134 and the cell tap assembly 130. Specifically, the plastic body 162 covers the column 150 of each band 146 and a portion of the connecting portion 156, while the fin 154 remains exposed. The column 150 of each band 146 can be coupled to the PCB134 by laser welding before the plastic body 162 is molded onto the cell tap assembly 130 and PCB134. This eliminates the need for brazing and improves the weld strength between the PCB134 and the cell tap assembly 130. The time spent on manufacturing the battery pack 100 is also reduced. In addition, the plastic body 162 provides more isolation between adjacent bands 146 to improve ingress protection.

[0071] See also Fig. 8A and 8B, which shows a USB battery 200. The USB battery 200 includes an inner housing 204, at least one battery cell (not shown) disposed in the inner housing 204, and a cell tapping strip 208 surrounding the inner housing 204. The inner housing 204 and the cell tapping strip 208 are arranged in a Fig. 8A 200 is represented by a dotted line. The USB battery 200 is covered by a first plastic body 212 and a second plastic body 216 formed by multi-shot molding. Specifically, the first plastic body 212 covers the inner housing 204 and the cell tapping strip 208 to properly fix the inner housing 204 and the cell tapping strip 208 in place. The second plastic body 216 is molded onto the first plastic body 212 to serve as an outer housing of the USB battery 200. In this way, at least one battery cell can be a 21700 battery cell with a capacity of 5Ah. In other specific embodiments, the USB battery 200 can be covered by a single plastic body.

[0072] See also Figures 9A-9D , which shows a plurality of battery cells 300. In the illustrated embodiment, the plurality of battery cells 300 is formed of three battery cells 300a, 300b, 300c. In some embodiments, the plurality of battery cells 300 may be formed of more than three battery cells. Each battery cell 300a, 300b, 300c has an outer surface 308a, 308b, 308c of a housing as an internal component of each battery cell 300a, 300b, 300c. The battery cells 300a, 300b, 300c are coupled to each other by a molded first plastic body 310. The first plastic body 310 couples the battery cells 300a, 300b, 300c together to form a single battery unit. The first plastic body 310 is molded onto the contacting outer surfaces 308a, 308b, 308c portions of adjacent battery cells 300a, 300b, 300c. In this way, the first plastic body 310 is disposed between the plurality of battery cells 300 .

[0073] Once the first plastic body 310 is molded onto the plurality of battery cells 300, the plurality of battery cells 300 are then permanently coupled to each other in the remaining process of manufacturing the battery pack. The PCB 312 and the terminals 316 are electrically coupled to the plurality of battery cells 300. The plurality of battery cells 300 undergo multi-shot molding to couple the battery cells 300, the PCB 312, and the terminals 316 into a single unit. In addition, the battery cells 300 and the PCB 312 are covered by the second plastic body 314, while the terminals 316 remain exposed. The housing 324 is then placed around the second plastic body 314 and the terminals 316 to form the battery pack.

[0074] See also Fig. 10A and 10B, which shows a plurality of battery cells 400 of another embodiment. In the illustrated embodiment, the plurality of battery cells 400 is formed by five battery cells 400a-400e. In some embodiments, the plurality of battery cells 400 may be formed by less than five battery cells. In other embodiments, the plurality of battery cells 400 may be formed by more than five battery cells. Each battery cell 400a-400e has an outer surface 404a-404e that serves as a housing for the internal components of each battery cell 400a-400e and the terminals 406a-406e formed on the respective ends of the battery cells 400a-400e. The battery cells 400a-400e are coupled together by a molded plastic body 408. The plastic body 408 is molded onto the plurality of battery cells 400 to form a single battery unit. The plastic body 408 is molded between the outer surfaces 404a-404e of adjacent battery cells 400a-400e. The plastic body 408 is also placed under the plurality of battery cells and forms a flat surface, which allows the battery cells 400 to form a single battery unit arranged in a horizontally laid position. A portion of the terminals 406a-406e is also covered by the plastic body 408.

[0075] Once the plurality of battery cells 400 are molded, the plurality of battery cells 400 are then permanently coupled to each other in the remaining process of manufacturing the battery pack. The battery core 412, PCB 416 and terminals 420 can then be positioned on top of the plurality of battery cells 400. A cell tap assembly 424 is also provided to electrically connect the plurality of battery cells to the PCB 416.

[0076] See also Fig.11A and 11B , which shows a battery pack 500 of another specific embodiment. The battery pack 500 includes a housing 504, a PCB 508, a battery core 512, a terminal partition 514, and a plurality of battery cells 516 surrounded by the battery core 512. The PCB 508 and the battery core 512 are placed in the housing 504 of the battery pack 500. A plurality of battery cells 516 are arranged in pairs in the battery core 512. Each pair of battery cells 516a, 516b is coupled together by a molded plastic body 524. The plastic body 524 is arranged between the paired battery cells 516a, 516b and covers a portion of the outer surfaces 524a, 524b facing the adjacent battery cells 516, 516b. The plastic body 524 also covers a portion of each terminal 528a, 528b formed on the respective ends of each battery cell 516a, 516b.

[0077] See also Fig. 12A and 12B, which shows another embodiment of a battery pack 600. The battery pack 600 includes a housing 604, a PCB 608, a terminal partition 610 mounted on the PCB 608, a battery core 612, and a plurality of battery cells 618 surrounded by the battery core 612. In the illustrated embodiment, the plurality of battery cells 618 is formed by 15 battery cells. In some embodiments, the plurality of battery cells 618 may be formed by more than 15 battery cells. In other embodiments, the plurality of battery cells 618 may be formed by less than 15 battery cells. The plurality of battery cells 618 are permanently coupled together by a molded plastic body 622. The plastic body 622 is disposed between adjacent battery cells 618 and around an outer surface 626 of the battery cell 618 disposed most toward the outside. In this way, the plastic body 622 eliminates any air gaps that may be formed between adjacent battery cells, thereby improving the thermal performance of the battery pack 600.

[0078] See also Figures 13A-13B , which shows another specific embodiment of a battery pack 700. The battery pack 700 and Fig. 12A and Fig. 12B The battery pack 600 is similar; therefore, the same structures will be marked with the same reference numerals plus "100".

[0079] The battery core is formed by a molded plastic body. Thus, the plurality of battery cells 718 are subjected to multi-shot molding to form the battery core 712 and the plastic body 722. In the multi-shot molding process, a first material is molded on the plurality of battery cells 718, and a second material is molded on the first material to form the battery core 712. During the molding process, other internal components of the battery pack 700 may also be covered with the second material to properly secure the components, such as the PCB 708 and the terminal 710. In other specific embodiments, the second material may form a fixed component configured to secure the PCB 708 and the terminal 710 to the battery core 712.

[0080] See also Fig.14A and 14B, which shows a plurality of battery cells 800 of another specific embodiment. Each battery cell 800 includes an outer surface 804 and a terminal 808 formed on a corresponding end of each battery cell 800. Each battery cell 800 is covered by a corresponding plastic body 812 that is molded. Each plastic body 812 covers a portion of the outer surface 804 of each battery cell 800. Specifically, the plastic body 812 does not extend to each end of the battery cell 800. The plastic body 812 also takes the form of a specific specific geometric shape. In the illustrated specific embodiment, the plastic body 812 has a hexagonal shape. In other specific embodiments, the plastic body 812 may have, but is not limited to, a circular shape, a linear shape, or a triangular shape. Since each battery cell 800 is covered by a corresponding plastic body 812, the plurality of battery cells 800 can be easily stacked and arranged in the housing of the battery pack. Each plastic body 812 also holds the battery cell 800 in place when placed in the battery pack, thereby preventing the battery cell 800 from rotating to reduce welding failure.

[0081] See also Figures 15A-15B , which shows a plurality of battery cells 900 according to another specific embodiment. Fig.14A and Fig. 14B The plurality of battery cells 800 are similar; therefore, like structures will be labeled with the same reference numerals plus "100".

[0082] Each plastic body 912 includes a plurality of slots 916 and a plurality of tabs 920. The plurality of slots 916 of each plastic body 912 are configured to receive corresponding tabs from adjacent battery cells 900. In this way, the plurality of battery cells 900 can be physically linked to each other when placed within the housing of the battery pack.

[0083] See also Fig.16A and 16B , which shows an inner battery housing 1000 for a battery pack. The inner battery housing 1000 includes a housing 1004, a first group of battery cells 1008, a second group of battery cells 1012, and heat pipes 1016. Respective heat pipes 1016 extend between the first and second groups of battery cells 1008, 1012. The first group of battery cells 1008 are permanently coupled together by a first plastic body 1018. The second group of battery cells 1012 are permanently coupled together by a second plastic body 1020. The first and second plastic bodies 1018, 1020 each have an opening 1024, 1026 ( Figures 17A-18B). The openings 1024, 1026 are configured to receive respective heat pipes 1016. The first and second groups of battery cells 1008, 1012 are disposed around the heat pipes 1016 so that each heat pipe 1016 removes heat from the battery cells 1008, 1012. The first and second plastic bodies 1018, 1020 also allow the heat pipes 1016 to be electrically isolated from the battery cells 1008a-d, 1012a-d ( Figures 17A-18B ).

[0084] See also Fig.17A and 17B , which shows a first group of battery cells 1008. Each battery cell 1008a-d of the first group of battery cells 1008 includes an outer surface 1028a-d and a terminal 1032a-d formed on a respective end of each battery cell 1008a-d. The first plastic body 1018 covers the entire outer surface 1028a-d of each battery cell 1008a-d, while the terminals 1032a-d remain uncovered.

[0085] See also Fig.18A and 18B , which shows a second group of battery cells 1012. Each battery cell 1012a-d of the second group of battery cells 1012 includes an outer surface 1034a-d and a terminal 1035a-d formed on a corresponding end of each battery cell 1012a-d. The second plastic body 1020 covers only a portion of the outer surface 1034a-d of each battery cell 1012a-d. Specifically, the second plastic body 1020 covers the portion of each outer surface 1034a-d facing the adjacent battery cell 1012a-d. When manufacturing the first and second groups of battery cells 1008, 1012, each group of battery cells 1008, 1012 is first molded together to form the first and second plastic bodies 1018, 1020, respectively. Then the corresponding heat pipe 1016 can be pressed into the first and second groups of battery cells 1008, 1020.

[0086] Apply the plastic body to Figures 8A-18B The plastic body eliminates air gaps between adjacent battery cells. In addition, the plastic body reduces movement of battery cells within the battery pack when the battery pack is dropped or subjected to shock. Figures 8A-18B In embodiments using multi-shot molding, thermal runaway within the battery pack can be avoided. Multi-shot molding facilitates phase transitions around the battery cells.

[0087] See also Figure 19-23, which shows another specific embodiment of a battery pack 2000. Some parts of the battery pack 2000 are removed for clarity. The battery pack 2000 includes a housing 2004, a plurality of battery cells 2012 stacked in the housing 2004, and a plurality of pads 2014 respectively disposed between each of the battery cells 2012. The plurality of battery cells 2012 are configured to supply power to an electrical device coupled to the battery pack 2000. In the illustrated specific embodiment, the battery cells 2012 are soft pack batteries.

[0088] In some embodiments, each battery cell 2012 can be subjected to a molding process. Specifically, the battery cell 2012a includes a main body 2016a and a pair of cell tabs 2020a, 2020b (i.e., terminal tabs) defined by positive and negative cell tabs. The pair of cell tabs 2020a extend from the main body 2016a. The main body 2016a of the battery cell 2012a is covered by a first plastic body 2028 that is injection molded. The first plastic body 2028 prevents external forces generated by vibration and falling actions from damaging the main body 2016a of the battery cell 2012a. The first plastic body 2028 also provides improved dimensional tolerances compared to battery cells without a plastic body. In addition, the first plastic body 2028 provides ingress protection by surrounding and protecting the main body 2016a, preventing water and debris from entering the battery pack 2000.

[0089] Once each battery cell 2012 is covered by the first plastic body 2028, the battery cell 2012 is then covered by the injection molded second plastic body 2032. The second plastic body 2032 acts as an inner housing, permanently coupling the battery cells 2012 together into a single battery unit. The second plastic body 2032 is formed into a rectangular base that fits within the interior space of the housing 2004 of the battery pack 2000 and defines an opening (not shown) configured to receive a front plate 2034 that engages the cell tabs 2020a, 2020b of each battery cell 2012. The second plastic body 2032 also includes a plurality of tabs 2036a, 2036b extending from the battery cell 2012.

[0090] The battery pack 2000 further includes a first PCB 2040 mounted on the second plastic body 2032, a second PCB 2044 mounted on the first PCB 2040, and a terminal 2048 mounted on the second PCB 2044. The terminal 2048 is configured to supply power from the battery cell 2012 to the electrical device. Specifically, a tab 2036a formed at an end of the second plastic body 2032 is inserted into an opening (not shown) defined in the first PCB 2040 to couple the first PCB 2040 to the second plastic body 2032. The tab 2036b formed on the side of the second plastic body 2032 is configured to latch on the side of the first PCB 2040 to further couple the first PCB 2040 to the second plastic body 2032.

[0091] The second PCB 2044 is covered by the third plastic body 2052. In this way, a portion of the electrical component 2054 mounted on the second PCB 2044 is covered by the third plastic body 2042. In some specific embodiments, the terminal 2048 is covered by the fourth plastic body 2056. The fourth plastic body 2056 is disposed between each terminal 2048 to form a wall around the terminal 2048 and improve the isolation of adjacent terminals 2048. The third plastic body 2052 and the fourth plastic body 2056 are both formed by a multi-shot molding process, which allows the third plastic body 2052 to be integrally molded with the fourth plastic body 2056. In other specific embodiments, the first plastic body 2028, the second plastic body 2032, the third plastic body 2052, and the fourth plastic body 2056 are made of the same material. In this way, the third plastic body 2052 is formed to couple the second PCB 2044 to the first PCB 2040 and the unit wing 2060 disposed on the side of the second plastic body 2032.

[0092] See also Fig.24, which shows a PCB3000. PCB3000 includes a plurality of electrical components 3004 mounted thereon. PCB3000 is configured to be placed in a battery pack (not shown) to control the charging and discharging of battery cells (not shown) in the battery pack. The battery pack also includes a terminal partition 3008 and a cell tap assembly 3012. The terminal partition 3008 is configured to electrically couple the battery pack to an electrical device. The cell tap assembly 3012 includes a plurality of strips 3016 and is configured to electrically couple the battery cells to the PCB3000. Each strip 3016 includes a column 3018 configured to extend through an opening (not shown) defined in the PCB3000, a fin (not shown) configured to engage the battery cell, and a connecting portion 3020 configured to interconnect the column 3018 and the fin. A portion of the terminal partition 3008 and a portion of the cell tap assembly 3012 are covered by a plastic body 3022. In this way, the cell tap assembly 3012 can be further isolated from the PCB3000. The plastic body 3022 is also disposed at the end portion 3024 of the terminal partition 3008 to position the terminal partition 3008 above the PCB 3000 without physically mounting the terminal partition 3008 to the PCB 3000. The terminals 3028 of the terminal partition 3008 extend from the end portion 3024 and are allowed to move freely because the terminals 3028 are not covered by the plastic body 3022.

[0093] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist which fall within the scope and spirit of one or more independent aspects of the invention.

Claims

1. An electrical device, characterized in that include: case; a printed circuit board, the printed circuit board being placed in the housing; and a plastic molded onto at least a portion of the printed circuit board; Wherein, the printed circuit board comprises: an electrical component mounted on the printed circuit board; and a plurality of openings defined in the printed circuit board; wherein the plastic covers at least some of the electrical components on the printed circuit board and the plurality of openings remain exposed.

2. The electrical device according to claim 1, wherein: Further including: a plurality of battery cells, the plurality of battery cells being disposed in the housing; a plurality of terminals mounted on the printed circuit board; and A cell tap assembly having strips, each strip including a post extending through a corresponding one of the plurality of openings of the printed circuit board, and each strip including at least one tab engaging one or more of the plurality of battery cells, the cell tap assembly being configured to electrically connect the plurality of battery cells to at least one of the electrical components on the printed circuit board.

3. The electrical device according to claim 2, wherein: Each of the plurality of openings and each of the pillars remain exposed.

4. The electrical device according to claim 2, wherein: The plastic covers at least some of the electrical components on the printed circuit board, at least a portion of the plurality of terminals, at least a portion of the cell tap assembly, and each of the plurality of openings.

5. The electrical device according to claim 1, wherein: The electrical device includes a battery pack.

6. An electrical device, characterized in that include: case; A plurality of battery cells, wherein the plurality of battery cells are disposed in the housing; plastic covering at least a portion of an exterior surface of each battery cell; The plastic is arranged to be at least partially between adjacent battery cells.

7. The electrical device according to claim 6, wherein: Each battery cell includes terminals disposed on respective ends of the battery cell.

8. The electrical device according to claim 7, wherein: The terminals remain exposed and the plastic couples the plurality of battery cells together into a single battery unit.

9. The electrical device according to claim 7, wherein: The plastic covers a portion of the outer surface of each battery cell and a portion of each of the terminals, the plastic is disposed at least partially between adjacent battery cells of the plurality of battery cells, and the plastic couples the plurality of battery cells together into a single battery unit.

10. The electrical device according to claim 7, wherein: The plastic covers a portion of the outer surface of each battery cell while the terminals remain exposed, the plastic is disposed at least partially between adjacent battery cells of the plurality of battery cells, and the plastic couples the plurality of battery cells together into a single battery unit.

11. The electrical device according to claim 7, wherein: Plastic is molded individually over each battery cell and covers a portion of the exterior surface of each battery cell while the terminals remain exposed.

12. The electrical device according to claim 11, wherein: The plastic molded onto each battery cell includes a plurality of tabs and a plurality of slots, and each slot is configured to receive a corresponding tab from an adjacent battery cell.

13. The electrical device according to claim 7, wherein: Further comprising at least one heat pipe, the plastic comprising an opening configured to receive the at least one heat pipe, and the plastic covering a portion of the outer surface of each battery cell, and the plurality of battery cells being arranged around the opening.

14. The electrical device according to claim 6, wherein: The at least one battery cell comprises a plurality of battery cells, the plurality of battery cells comprising soft-pack batteries, each soft-pack battery comprising a main body and at least one terminal tab, the at least one terminal tab extending from the main body, and a majority of the main body of each soft-pack battery being covered by the plastic.

15. The electrical device according to claim 14, wherein: The plastic is a first plastic, and further includes a second plastic molded on at least a portion of the soft pack battery to cover the first plastic and form a battery core.

16. The electrical device according to claim 15, wherein: Further including: a first printed circuit board, the first printed circuit board being coupled to the second plastic via a plurality of tabs formed thereon; a second printed circuit board mounted on the first printed circuit board; and A third plastic is molded on at least a portion of the second printed circuit board.

17. The electrical device according to claim 16, wherein: Further including: a terminal partition mounted on the second printed circuit board; and a fourth plastic molded on at least a portion of the terminal partition, and The fourth plastic covers at least a portion of the third plastic.

18. The electrical device according to claim 17, wherein: The first plastic, the second plastic, the third plastic and the fourth plastic are made of the same material.

19. An electrical device, characterized in that include: Battery cells; A plastic is molded around a majority of the battery cell such that the plastic adheres to the battery cell without an adhesive, wherein the plastic serves as an outer housing for the electrical device.

20. The electrical device according to claim 19, wherein: The plastic includes a first plastic body molded on the inner shell of the battery cell and a second plastic body molded on the first plastic body, wherein the second plastic body serves as the outer shell.

Images