Battery Module Conductive Tab Sealing Against Water Ingress
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Solution Overview
Problem
Conventional battery systems are vulnerable to water ingress and environmental contaminants, leading to corrosion and potential failure, especially in portable devices where terminals are often exposed.
Innovation Solution
The battery system design includes a module with a conductive tab and electrode tab configuration that provides enhanced protection against water ingress and contaminants, featuring a curvature in the conductive tab for secure coupling, a spacer for component protection, and multiple layers of water-resistant tape for comprehensive sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional battery terminals are exposed for electrical connection, then ease of operation is improved, but reliability deteriorates due to water ingress and environmental contaminants causing corrosion
Solution Approach 1:
The patent applies water-resistant tape (a flexible film) to wrap around the conductive tab and seal it to the module housing. This creates a protective barrier that prevents water and contaminants from reaching the conductive tab while maintaining its electrical function, thus resolving the contradiction between accessibility and corrosion resistance
Solution Approach 2:
The conductive tab is nested within the module housing structure, with the tab extending into the housing interior and being sealed by the water-resistant tape. This nesting arrangement protects the terminal while keeping it electrically connected to both the electrode and external circuitry
2Volume of moving object
If multiple components are integrated into the module for compact design, then volume of moving object is reduced, but device complexity increases due to additional sealing and protection requirements
Solution Approach 1:
The patent combines the conductive tab, electrode tab, and sealing structure into a single integrated assembly. The water-resistant tape serves multiple functions simultaneously: sealing the conductive tab, providing mechanical support, and preventing contaminant ingress. This merging reduces the number of separate components needed while maintaining protection
3Adaptability or versatility
If the conductive tab is extended to allow flexible routing, then adaptability is improved, but object-generated harmful factors increase due to larger surface area exposed to contaminants
Solution Approach 1:
The water-resistant tape wraps around the conductive tab in a flexible manner, accommodating different routing configurations while maintaining a continuous seal. This allows the tab to be routed adaptably without increasing contaminant exposure, as the tape conformally seals the tab regardless of its shape or position
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
This design effectively limits water ingress and protects against environmental contaminants, enhancing the robustness and reliability of battery systems by creating a secure seal around conductive and corrodible components, thereby preventing corrosion and ensuring proper functioning.
Implementation Method 1
The spacer may include an adhesive coupling the spacer with the circuit board
Implementation Method 2
a first water resistant tape extending about the module and across the first end of the conductive tab. The system may also include a second water resistant tape extending across the distal portion of the electrode tab and contacting the first water resistant tape at the first surface of the module
Data Source
AI summary
Battery systems according to embodiments of the present technology may include a battery cell having an electrode tab extending from an edge of the battery cell. The systems may also include a module electrically coupled with the battery cell. The module may be characterized by a first surface, a height, and a second surface opposite the first surface. A conductive tab coupled along the first surface of the module may extend from a first end parallel to a plane of the first surface. The conductive tab may be characterized by a curvature proximate a midpoint of the conductive tab. A distal region of the conductive tab may return back across the first surface of the module substantially parallel to the first surface. A distal portion of the electrode tab may be fixedly coupled with the distal region of the conductive tab.