Integrated component cap and spacer for battery pack

Patent metadata

Field	Value
Publication number	US-10062886-B2
Application number	US-201614991638-A
Country	US
Kind code	B2
Filing date	Jan 8, 2016
Priority date	Sep 4, 2015
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A battery pack is disclosed. The battery pack includes a cell with a spacer, and a cap mounted on the spacer. The spacer and cap are mated to form a cavity to accommodate the components (i.e. busbars, circuit board, an insulator) of the battery pack. The spacer and cap have a series of mating surfaces for the components, wherein the mating surfaces have different heights to be recessed relative to each other to create spaces for accommodating the components. The recesses, channels, steps and raised portions correspond in geometry to the components so that they can be assembled while removing the tolerance accumulation associated with multiple standoffs.

First claim

What is claimed is:

1. A battery pack, comprising:
a cell having a first side;
a spacer comprising:
a first side and a second side, the second side disposed opposite of the first side, wherein the first side of the spacer is mounted to the first side of the cell;
a plurality of mating surfaces including a cap mating surface, a circuit board mating surface, a first busbar mating surface, and a second busbar mating surface, wherein the plurality of mating surfaces have different heights;
wherein the first busbar mating surface and the second busbar mating surface are formed on the first side of the spacer; and
wherein the cap mating surface and the circuit board mating surface are formed on the second side of the spacer;

a circuit board, wherein the circuit board is disposed on the circuit board mating surface of the spacer;
first and second busbars, wherein the first and second busbars contact the first and second busbar mating surfaces, respectively; and
a first cap having an interior surface affixed to the cap mating surface of the spacer.

2. The battery pack of claim 1 wherein the height of the first busbar mating surface and the height of the second busbar mating surface are different.

3. The battery pack of claim 1 wherein the circuit board is a flexible printed circuit board.

4. The battery pack of claim 1 further comprising a flex cable, wherein the flex cable is connected to the circuit board and the spacer further comprises a flex cable channel, wherein the flex cable channel has a height that is recessed relative to the height of the circuit board mating surface.

5. The battery pack of claim 1 further comprising an overwrap, wherein the overwrap is disposed around an outer circumferential surface of the cell.

6. The battery pack of claim 5 wherein the cell has a second side opposing the first side and the overwrap has a length that extends from an edge of the first cap to an edge of the second side of the cell.

7. The battery pack of claim 1 wherein the cell has a second side opposing the first side and further comprising a second cap disposed on the second side of the cell.

8. The battery pack of claim 7 further comprising an overwrap, wherein the overwrap is disposed around an outer circumferential surface of the cell and has a length that extends from an edge of the first cap to an edge of the second cap.

9. The battery pack of claim 1 further comprising:
the spacer further comprising an insulator mating surface, wherein the insulator mating surface has a height that is greater than the height of the first and second busbar mating surfaces and is recessed relative to the height of the circuit board mating surface; and
an insulator, wherein the insulator is disposed on the insulator mating surface.

10. The battery pack of claim 9 wherein the height of the first and the second busbar mating surfaces are recessed relative to the insulator mating surface such that the first and the second busbars disposed on the first and the second busbar mating surfaces, respectively, are recessed relative to insulator mating surface.

11. A battery pack, comprising:
a cell having a first side with a first terminal;
a spacer comprising:
a first side and a second side, the second side disposed opposite of the first side, wherein the first side of the spacer is mounted to the first side of the cell;
an opening to accommodate the first terminal;
a plurality of mating surfaces including a cap mating surface, a circuit board mating surface, a first busbar mating surface, and a second busbar mating surface, wherein the plurality of mating surfaces have different heights such that the circuit board mating surface has a height that is recessed relative to a height of the cap mating surface;
wherein the first and the second busbar mating surfaces are formed on the first side of the spacer; and
wherein the cap mating surface and the circuit board mating surface are formed on the second side of the spacer;

a circuit board, wherein the circuit board is disposed on the circuit board mating surface of the spacer;
first and second busbars, wherein the first and second busbars contact the first and second busbar mating surfaces, respectively; and
a first cap having an interior surface affixed to the cap mating surface of the spacer.

12. The battery pack of claim 11 wherein the height of the first busbar mating surface and the height of the second busbar mating surface are different.

13. The battery pack of claim 11 further comprising a flex cable, wherein the flex cable is connected to the circuit board and the spacer further comprises a flex cable channel, wherein the flex cable channel has a height that is recessed relative to the height of the circuit board mating surface.

14. The battery pack of claim 11 further comprising an overwrap, wherein the overwrap is disposed around an outer circumferential surface of the cell.

15. The battery pack of claim 14 wherein the cell has a second side opposing the first side and the overwrap has a length that extends from an edge of the first cap to an edge of the second side of the cell.

16. A battery pack, comprising:
a cell having a first side;
a spacer comprising:
a first side and a second side, the second side disposed opposite of the first side, wherein the first side of the spacer is mounted to the first side of the cell;
a plurality of mating surfaces including a cap mating surface, a circuit board mating surface, a first busbar mating surface, and a second busbar mating surface, wherein the plurality of mating surfaces have different heights;
wherein the first busbar mating surface and the second busbar mating surface are formed on the first side of the spacer; and
wherein the cap mating surface and the circuit board mating surface are formed on the second side of the spacer;

a circuit board, wherein the circuit board is disposed on the circuit board mating surface of the spacer;
first and second busbars, wherein the first and second busbars contact the first and second busbar mating surfaces, respectively;
a first cap having an interior surface affixed to the cap mating surface of the spacer; and
an overwrap, wherein the overwrap is disposed around an outer circumferential surface of the battery pack and extends at least a length of the cell, a length of the spacer and a length of the first cap.

Assignees

• Apple Inc

Inventors

• Bohney Nathan J

Classifications

• H01M10/425 Primary

  Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00) · CPC title

• H01M50/593

  Spacers; Insulating plates · CPC title

• H01M50/289

  characterised by spacing elements or positioning means within frames, racks or packs (spacing elements inside cells other than separators, membranes or diaphragms H01M50/471) · CPC title

• H01M50/284

  with incorporated circuit boards, e.g. printed circuit boards [PCB] · CPC title

• H01M50/204

  Racks, modules or packs for multiple batteries or multiple cells · CPC title