Removable Battery Assembly with Flex Circuit Alignment
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Solution Overview
Problem
Smaller portable electronic devices, such as cellular telephones, portable media players, and PDAs require a specialized battery system that existing battery coupling methods do not adequately address, particularly in terms of power transfer and user-replaceable solutions.
Innovation Solution
A removable battery assembly comprising a battery cell, a battery connector with conductive pads for power and temperature sensing, and a flex circuit for electrical coupling, secured using adhesives and mechanical fasteners, allowing for easy alignment and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a battery is made replaceable by the user, then ease of operation is improved, but device complexity increases due to additional components like battery connectors and flex circuits
Solution Approach 1:
The battery system is divided into separate replaceable components: the battery cell can be removed and replaced by the user, while the battery connector and flex circuit remain integrated with the device. This segmentation allows easy battery replacement without replacing the entire power system.
Solution Approach 2:
A flex circuit is introduced as an intermediary component that electrically couples the battery cell to the battery connector. This flexible circuit board enables reliable electrical connection while accommodating the removable nature of the battery cell, solving the complexity issue through a specialized intermediate component.
2Ease of manufacture
If conductive tabs on battery surface are used for power transfer, then ease of manufacture is improved, but power transfer reliability deteriorates in smaller portable devices
Solution Approach 1:
The flex circuit serves as an intermediary between the battery cell's conductive tabs and the device's power system. It provides a more reliable and controlled electrical connection than direct tab contact, ensuring stable power transfer while maintaining manufacturability through standardized flex circuit fabrication processes.
Solution Approach 2:
The direct mechanical contact of conductive tabs is supplemented and enhanced by the flex circuit, which provides a more reliable electrical connection through its flexible, conformal contact surfaces. This substitution improves power transfer reliability while maintaining ease of assembly.
3Ease of manufacture
If adhesive is used to secure battery cell, then ease of manufacture is improved, but ease of operation deteriorates due to difficulty in battery replacement
Solution Approach 1:
The battery assembly is segmented into the battery cell and the battery connector assembly. The adhesive secures only the battery cell to the connector assembly, not the entire battery system to the device. This allows the battery cell to be easily replaced by detaching it from the connector, which remains mounted in the device.
Solution Approach 2:
The battery connector assembly acts as an intermediary that remains permanently attached to the device while the battery cell can be independently replaced. The adhesive secures this intermediate component, providing stable mounting while allowing battery cell replacement through the connector interface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures reliable power transfer, efficient recharging, and user-friendly replacement of batteries in portable electronic devices, enhancing usability and reducing environmental impact by allowing battery cell replacement while reusing the battery connector.
Implementation Method 1
an adhesive layer attached to a surface of the battery cell may bind to the electronic device
Implementation Method 2
a flex circuit for electrically coupling the battery cell to the battery connector
Implementation Method 3
The battery connector may include one or more conductive pads for transferring power
Implementation Method 4
the battery connector may include one or more pads for sensing the temperature of the electronic device
Data Source
AI summary
A battery assembly for use in an electronic device is provided. The battery assembly may include a battery cell (e.g., a rechargeable battery cell), a battery connector for providing power from the battery cell to the electronic device, and a flex circuit electrically coupling the battery cell to the electronic device. The battery connector may be located adjacent the battery cell, and may include one or more alignment mechanisms for ensuring that conductive pads of the battery connector align properly with corresponding conductive elements of the electronic device. The battery cell may be fixed to the electronic device using an adhesive layer (e.g., double sided tape) placed between the cell and the electronic device. A tab may extend beyond the periphery of the battery cell to allow a user to pull or peal the battery cell from the electronic device for replacement or repair. In some embodiments, a tool may be used to grasp the tab.