Overmolded Battery Module With Conductive Tabs For Compact Form Factor
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Solution Overview
Problem
Conventional battery systems face challenges in accommodating smaller device form factors due to space constraints, as larger batteries require more housing space and restrict the placement of associated components, limiting the available volume and geometry for battery cell placement.
Innovation Solution
The battery system incorporates a module with conductive tabs and molds that allow for compact positioning of battery components, including a circuit board and electronic devices, which are electrically coupled with the battery terminals, enabling efficient use of space and accommodating the battery's geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If larger batteries are used to increase capacity, then energy storage increases, but the available space for battery components and placement options is reduced
Solution Approach 1:
The patent utilizes the lateral edge dimension of the battery by positioning the port and associated components along the lateral edge rather than only on the main surfaces. This dimensional approach allows the module to accommodate battery terminals and conductive elements in three-dimensional space, effectively using vertical and lateral dimensions to resolve space constraints while maintaining battery capacity.
Solution Approach 2:
The module structure nests multiple components within a compact configuration: the circuit board is positioned adjacent to the battery, conductive tabs extend from the module to connect with battery terminals, and the port is integrated into the lateral edge structure. This nested arrangement allows maximum component integration within minimal space, resolving the contradiction between battery capacity and component placement space.
2Length of stationary object
If battery components are positioned to accommodate smaller device form factors, then device size reduces, but component placement options are restricted
Solution Approach 1:
The patent applies local quality by concentrating battery-related components (module, circuit board, port, conductive tabs) in a specific localized region along the lateral edge of the battery. This localized configuration allows the rest of the device to maintain compact dimensions while the battery components are adapted to fit within this specific zone, thus reducing overall device size without sacrificing component placement flexibility.
Solution Approach 2:
The conductive tabs are designed with flexible positioning capabilities, extending from the module to connect with battery terminals at various positions. This dynamic configuration allows the component placement to adapt to different battery geometries and device form factors, maintaining versatility while accommodating smaller device sizes.
3Reliability
If the module is positioned adjacent to the battery with conductive tabs extending to terminals, then electrical coupling is achieved, but space for component placement is limited
Solution Approach 1:
The conductive tabs function as thin, flexible conductive elements that extend from the module to the battery terminals. These thin-film-like structures provide reliable electrical coupling while occupying minimal space, allowing the module to be positioned adjacent to the battery without significantly increasing the volume required for component placement.
Data Source
AI summary
Battery systems according to embodiments of the present technology may include a battery including a first electrode terminal and a second electrode terminal accessible along a first surface of the battery. The battery systems may also include a module electrically coupled with the battery. The module may include a first mold extending toward the battery. The first mold may define a recess along a first surface of the first mold proximate the first electrode terminal and the second electrode terminal. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The first electrode terminal may be at least partially positioned within a space defined by the recess defined by the first mold. The module may also include a second conductive tab electrically coupling the module with the second electrode terminal.