Flexible Circuit Conductive Pads for Battery Connection
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Solution Overview
Problem
Conventional methods for connecting batteries to electronic devices are costly and increase the size and complexity of the devices due to the use of battery holders or pre-attached tabs, which are not compatible with flexible circuits.
Innovation Solution
The use of conductive pads on a flexible circuit, formed using surface mount technology and reflow processes, directly bonded or welded to the battery terminals, allowing for a compact and cost-effective attachment method without adhesives or mechanical pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery holders or pre-attached tabs are used to connect battery to electronic devices, then the connection reliability is improved, but the device size and complexity increase
Solution Approach 1:
The patent extracts the battery holder and pre-attached tabs from the system, eliminating these separate components. Instead, the flexible circuit board itself forms the connection structure through its conductive traces and pads, directly integrating the connection function into the circuit board without requiring additional battery holder components or pre-attached tabs.
Solution Approach 2:
The patent merges the battery connection function with the flexible circuit board structure. The conductive traces and pads on the flexible circuit board are designed to directly contact and connect to the battery terminals, combining the electrical connection function with the circuit board's structural role, eliminating the need for separate battery holders or tabs.
2Reliability
If conventional battery holders or pre-attached tabs are used to connect battery to electronic devices, then the connection reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent removes the battery holder and pre-attached tabs from the component list, reducing the number of parts that need to be procured, managed, and assembled. This extraction of unnecessary components directly reduces manufacturing costs while maintaining connection reliability through the integrated flexible circuit board design.
Solution Approach 2:
By merging the battery connection function into the flexible circuit board's conductive traces and pads, the patent reduces the total component count and simplifies the assembly process. This integration eliminates the need for separate battery holder assemblies and pre-attached tabs, thereby reducing manufacturing costs through fewer parts and simpler assembly operations.
3Volume of moving object
If the flexible circuit is bent or folded to connect pads to battery terminals, then the device size is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent employs a flexible circuit board that can be dynamically bent or folded into different configurations to achieve compact device sizes. The flexible nature of the circuit board allows it to adapt to various shapes and orientations, enabling space-efficient designs while maintaining electrical connectivity through its flexible conductive traces and pads.
Solution Approach 2:
The patent changes the physical state and properties of the circuit board from rigid to flexible, allowing it to be bent and folded without breaking. This parameter change in material flexibility enables the circuit board to conform to compact device geometries while maintaining electrical connectivity, resolving the conflict between device size reduction and manufacturing precision requirements.
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 approach reduces manufacturing costs and size, enables a more compact design, and avoids damage to the battery and surrounding circuitry, as the flexible circuit can be bent or folded to connect the pads to the terminals, providing a reliable and efficient battery connection.
Implementation Method 1
Each of the first and second conductive pads includes a solder material
Implementation Method 2
the first conductive pad, the second conductive pad, the microprocessor, and the one or more circuitry components are formed on a surface of the flexible circuit that is inwardly facing towards the battery
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
Disclosed are systems, devices, and methods for connecting a flexible circuit to a battery. Conductive pads are formed simultaneous with mounting and reflowing circuitry components on a flexible circuit, where the conductive pads serve as preformed tabs capable of being joined to terminals of a battery. The flexible circuit can be bent in a manner so that the conductive pads are positioned adjacent to the positive and negative terminals of a battery, such as a coin cell battery. The conductive pads can be attached to the terminals to form a cost-efficient and space-efficient design connecting the battery to the flexible circuit.