Direct Placement Battery Modules With Molded Recesses
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Solution Overview
Problem
Conventional battery systems face challenges in compactly integrating battery control components due to space constraints in devices with reduced sizes, where larger batteries require more housing space and conventional designs often lead to damage during manufacturing and increased risk of fluid contact.
Innovation Solution
The battery system design includes a battery cell with an electrode tab extending from its edge, a module electrically coupled with the cell, and a conductive tab that is curved and recessed within a mold, along with a flexible coupling that connects to a system board, allowing for compact vertical positioning and protection of components within a defined volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional battery designs are used, then battery capacity can be maintained, but the system occupies excessive space and components are vulnerable to damage
Solution Approach 1:
The module is nested directly onto the battery cell, with the mold encapsulating the circuit board and positioning it within the volume defined by the battery cell height. The conductive tab is nested through the mold to connect the circuit board with the electrode tab, creating a compact integrated structure that reduces overall system volume while protecting components.
Solution Approach 2:
The design transitions from a lateral arrangement of components to a vertical arrangement, utilizing the height dimension of the battery cell. The flexible coupling extends vertically from the circuit board, and the module is positioned vertically on the cell, allowing all components to fit within the defined volume without extending beyond the battery cell's height.
2Volume of moving object
If battery components are compactly integrated, then space is reduced, but manufacturing complexity increases
Solution Approach 1:
The mold serves as an integrated component that simultaneously encapsulates the circuit board, positions the flexible coupling, and guides the conductive tab. This merging of multiple functions into a single mold structure simplifies manufacturing by reducing the number of separate assembly steps and components.
Solution Approach 2:
The mold is designed with pre-formed recesses and channels that automatically position the conductive tab and flexible coupling during the molding process. This preliminary action of pre-positioning components within the mold structure eliminates the need for complex post-assembly alignment steps, reducing manufacturing complexity.
3Ease of operation
If components extend beyond the battery volume, then connectivity is easier, but device integrity is compromised
Solution Approach 1:
The flexible coupling is implemented as a thin, flexible circuit board that can bend and extend within the defined volume. This flexible film structure maintains electrical connectivity between the module and system board while conforming to the compact vertical arrangement, ensuring device integrity without compromising connectivity.
4Use of energy by moving object
If larger batteries are used, then energy capacity increases, but available space for system materials decreases
Solution Approach 1:
The design utilizes the vertical height dimension of the battery cell to arrange system materials, rather than spreading them laterally. By positioning the module, flexible coupling, and conductive tab within the vertical volume defined by the battery cell height, the design maximizes energy capacity while accommodating all necessary system materials within the available space.
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 a first side of the battery cell. The battery system may also include a module electrically coupled with the battery cell. The module may include a mold defining a recess along a first side of the module. The module may also include a conductive tab extending from the first side of the module. The conductive tab may be coupled with the electrode tab. The electrode tab may be characterized by a curvature along a length of the electrode tab, and a distal end of the electrode tab may be positioned within the recess defined by the mold.