Flat Battery Unit With Through-Hole Terminals
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Solution Overview
Problem
Conventional battery units with flat batteries face challenges in compactness due to the size of protection circuits and terminals, making them unsuitable for small devices.
Innovation Solution
A battery unit design where a substrate with circuit components is fixed to the flat battery, with terminals formed on the opposite side to overlap the battery, allowing for compact thickness and radial reduction, and using a sealing can to secure the substrate and prevent deformation effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a substrate with protection circuit and terminals is provided for a flat battery, then the battery unit achieves functional completeness, but the substrate becomes larger than the flat battery itself, increasing the overall size
Solution Approach 1:
The patent applies dimensionality change by moving the terminals from the planar surface of the substrate to the thickness direction. Through-holes are formed in the substrate, allowing terminals to extend from one surface to the other, utilizing the Z-axis dimension. This enables compact substrate design where terminals pass through the substrate thickness rather than occupying additional planar area, resolving the contradiction between functional completeness and substrate size.
2Length of stationary object
If the battery unit is designed to be compact in thickness direction by mounting circuit components on the substrate surface, then the overall thickness is reduced, but the circuit components become exposed and accessible to users
Solution Approach 1:
The patent applies the nesting principle by placing circuit components on one surface of the substrate while mounting the flat battery on the opposite surface, with terminals passing through the substrate like nested layers. This layered arrangement allows the circuit components to be protected between the substrate and battery assembly, reducing exposure while maintaining compact thickness. The terminals extend through the nested structure to provide electrical connection without increasing overall thickness.
3Area of stationary object
If the substrate is fixed directly to the flat battery surface, then the assembly is compact, but the substrate is affected by battery deformation, compromising electrical connection reliability
Solution Approach 1:
The patent applies segmentation by dividing the mounting structure into distinct functional zones: the substrate is fixed to the battery surface at specific locations (edge portions or center) rather than covering the entire surface. This selective fixation allows the substrate to remain compact while reducing the transmission of deformation forces across the entire assembly. The segmented mounting approach maintains electrical connection reliability by isolating critical connection points from deformation effects.
Data Source
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Figure 3
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AI summary
A battery unit provided with a flat battery and a substrate having a circuit formed thereon is provided in a compact form as a whole. The battery unit (1) includes a flat battery (2) in a flat shape having an upper surface and a bottom surface and a substrate (61) fixed to one surface of the flat battery (2). A circuit component (62) is mounted on a surface of the substrate (61) on a side of the flat battery (2), and a positive electrode terminal (68) (charging terminal) electrically connected to a positive electrode side of the flat battery (2) and a negative electrode terminal (66) (GND terminal) electrically connected to a negative electrode side of the flat battery (2) are formed on a surface of the substrate (61) on the opposite side to the flat battery (2).