Inventus Power, Inc.

Daniel Paul Rose

Elijah Brett Goldin

Timothy James Vallaro

Marcelo Nicosia

Horace Cesar Rodriguez

Bryan Rossman

Ilyas Ayub

William Mark Batts

Anvin Joe Manadan

Kevin James Zwart

Paul John Kudrna

John Lundeen

Battery

Aspects described herein relate to a conformal wearable battery (CWB) and/or a system that includes plural battery cells. The CWB and/or system includes a flexible printed circuit board assembly (PCBA). The plurality of battery cells are arranged in a pattern on a same side of the flexible PCBA. One or more examples of the flexible PCBA include cutouts and electrical connection pads. A battery cell is connected to an electrical connection pad via electrically conductive elements, such as tabs. In one or more examples, the electrically conductive elements extend through the cutouts in the flexible PCBA. In other examples, the electrically conductive elements wrap around an edge of the flexible PCBA.

Conformal wearable battery and system

A molded housing of a conformal wearable battery (CWB) encloses an electronic component and include an electrically conductive contact component embedded within an exterior wall to conduct electricity between an interior and an exterior of the casing. A flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) is enclosed in a cavity within the molded housing and includes attachment sections for a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. A visco-elastic shock-absorbing member installed between the upper and lower portion of the flexible PCBA when configured in a folded configuration. Each battery cell is joined to the flexible PCBA via a welding process. Each battery cell has a visco-elastic shock-absorbing member attached individually to each battery cell of the plurality of battery cells. When folded to fit within the cavity of the molded housing, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.

Conformal wearable battery

A battery system with a passive thermal management system is formed from a plurality of battery cells arranged on a printed circuit board assembly. In some cases, the printed circuit board assembly may include a flexible printed circuit board that is folded along an axis forming an upper and lower portion of the printed circuit board assembly. The thermal management system may include fire-blocking foam members individually attached to each battery cell. The battery cells may be arranged in a grid-like pattern to allow for a spacing arrangement between the battery cells to keep a failing battery cell from negatively affecting an adjacent battery cell. In addition, the flexible printed circuit card may include a fuse for each battery cell to shut off any current flow to a faulty battery cell if it begins to fail causing current flow to exceed beyond a predetermined current limit. The battery system may be a conformal wearable battery.

Thermal management for a conformal wearable battery

A battery system includes a plurality of non-cylindrical shaped battery cells arranged on, and physically affixed to, a flexible printed circuit board (PCB). The PCB may include a bend axis that facilitates folding of the flexible PCB to form an upper portion of the flexible PCB and a lower portion of the flexible PCB. A central stiffener may be positioned between the upper portion and the lower portion of the flexible PCB using an adhesive foam tape to form a battery assembly. The battery system may include a flexible housing with an internal cavity that receives the battery assembly. The central stiffener, and the adhesive foam tape, may provide a degree of rigidity and/or absorption to the PCB to reduce localized deformation of the PCB when the battery system experiences shock forces and to prevent damage to components of the battery assembly. The stiffener may be formed from non-metallic material.

Electrical contact

A molded housing may enclose an electronic component and include an electrically conductive contact component embedded within an exterior wall to conduct electricity between an interior and an exterior of the casing. The contact component may include two knurled areas separated by a recessed groove. The knurled areas and recessed groove may be coplanar with the exterior wall. The knurled areas and recessed groove may form an interface with the molded casing to seal the casing against ingress of liquid into the interior. The molded casing may include an upper housing and a lower housing formed from a combination of a rigid member and a flexible member. The rigid member may have a plurality of rigid regions, and the flexible member may have a plurality of flexible regions formed between neighboring rigid regions. The flexible member may be molded onto the rigid member using a two-shot injection molding process. In some examples, the contact component may be secured to a contact carrier, where the contact carrier is then secured to the exterior housing.

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Wheaton, IL, United States of America

Daniel Paul Rose