# US 12,114,426 B2 · Conformal wearable battery and system

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 12,114,426 B2
- Document ID: US12114426B2
- Status: Granted
- Kind: B2
- Application number: 18/128,477
- Filed: 2023-03-30
- Published: 2024-01-18
- Granted: 2024-10-08
- Earliest claimed: 2020-09-30
- Assignees: Inventus Power, Inc.
- Applicants: Inventus Power, Inc.
- Inventors: Elijah Brett Goldin; Ilyas Ayub; William Mark Batts; Anvin Joe Manadan; Timothy James Vallaro; Bryan Rossman; Daniel Paul Rose; Kevin James Zwart; Marcelo Nicosia; Horace C. Rodriguez
- Web page: https://patentgrep.com/patent/US12114426B2

## CPC

- H05K 1/118: {specially for flexible printed circuits, e.g. using folded portions}
- H01M 10/425: {Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00)}
- H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence)
- H01M 50/213: adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence)
- H01M 50/284: with incorporated circuit boards, e.g. printed circuit boards [PCB]
- H01M 50/502: Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
- H01M 50/516: by welding, soldering or brazing
- H01M 50/519: comprising printed circuit boards [PCB]
- H05K 1/117: {Pads along the edge of rigid circuit boards, e.g. for pluggable connectors}
- H05K 1/181: associated with surface mounted components
- H05K 1/189: characterised by the use of flexible or folded printed circuits
- H05K 3/303: with surface mounted components (H05K3/32 takes precedence)
- H01M 2220/30: Batteries in portable systems, e.g. mobile phone, laptop
- H05K 2201/09072: Hole or recess under component or special relationship between hole and component
- H05K 2201/10037: Printed or non-printed battery
- H05K 2203/107: Using laser light
- Y02E 60/10: Energy storage using batteries
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

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.

## Claims

### Claim 1

A system comprising:
a first plurality of battery cells, wherein a first battery cell of the first plurality of battery cell includes a first pair of electrically conductive elements;
a second plurality of battery cells, wherein a second battery cell of the second plurality of battery cell includes a second pair of electrically conductive elements;
a flexible printed circuit board (PCB) comprising:
a plurality of battery cell connection areas disposed in a grid-like pattern along a first surface of the flexible PCB;
a plurality of cutout pairs disposed adjacent and parallel to an edge of the plurality of battery cell connection areas, wherein the plurality of cutout pairs is arranged as adjacent a majority of the plurality of battery cell connection areas; and
a plurality of electrical connection pads disposed on a second surface of the flexible PCB opposite the first surface, wherein a majority of the plurality of electrical connection pads are arranged adjacent the plurality of cutout pairs, wherein the plurality of electrical connection pads comprise an electrically conductive surface coating; and
a sealed flexible housing,
wherein the first pair of electrically conductive elements connects, around an edge of the flexible PCB, to a corresponding electrical connection pad of the plurality of electrical connection pads forming a first electrical connection,
wherein the second pair of electrically conductive elements extends through a cutout pair of the plurality of cutout pairs forming a second electrical connection to a corresponding electrical connection pad pair of the plurality of electrical connection pads,
wherein the flexible PCB is disposed within an interior cavity of the sealed flexible housing, and
wherein the flexible PCB is in a folded configuration.

### Claim 2 (depends on 1)

The system of claim 1, wherein the first plurality of battery cells and the second plurality of battery cells comprise pouch cell packaged polymer lithium-ion.

### Claim 3 (depends on 1)

The system of claim 1, wherein a first electrical connection between a first electrically conductive element of the first pair of electrically conductive elements and the corresponding electrical connection pad of the plurality of electrical connection pads are joined with a weld.

### Claim 4 (depends on 1)

The system of claim 1, wherein a connection pad of the plurality of electrical connection pads has a circular shape with a diameter that is within a range of 1.8 times and 3 times a width of an electrically conductive element of the first pair of electrically conductive elements.

### Claim 5 (depends on 1)

The system of claim 1, wherein the electrically conductive surface coating comprises an electroless nickel immersion gold (ENIG) surface coating.

### Claim 6 (depends on 1)

The system of claim 1, wherein the electrically conductive surface coating comprises a lead-free immersion silver surface coating.

### Claim 7 (depends on 1)

The system of claim 1,
wherein the first pair of electrically conductive elements comprises a first tab,
wherein the second pair of electrically conductive elements comprises a second tab, and
wherein a first height of the first electrical connection is within a range of 1.2 to 3 times a thickness of the first tab and a second height of the second electrical connection is within a range of 1.2 to 3 times a thickness of the second tab.

### Claim 8 (depends on 1)

The system of claim 1, wherein the sealed flexible housing comprises:
a first shell formed from a first member having a first plurality of rigid regions and a second member that has a first flexible region located between a first rigid region and a second rigid region of the first plurality of rigid regions, and wherein the first shell includes a front wall with an outward facing surface formed from outward facing surfaces of the first plurality of rigid regions and an outward facing surface of the second member, wherein each rigid region of the first plurality of rigid regions is connected to an adjacent rigid region, by a channel on the first member; and
a second shell attached to the first shell, wherein the second shell includes a third member having a second plurality of rigid regions and a fourth member that has a second flexible region located between a first rigid region and a second rigid region of the second plurality of rigid regions, and wherein the second shell has an outward facing surface formed from outward facing surfaces of the second plurality of rigid regions and an outward facing surface of the second member,
wherein the first member is formed as a unitary member formed from a first material and the second member is joined to the first member,
wherein the second member is formed from a second material and wherein a first hardness of the first material is greater than a second hardness of the second material, and
wherein the first shell connects to the second shell to form an interior cavity that receives the first plurality of battery cells and the second plurality of battery cells.

### Claim 9 (depends on 3)

The system of claim 3, wherein the weld is formed using a laser welding process.

### Claim 10

A conformal wearable battery comprising:
a plurality of battery cells, each battery cell of the plurality of battery cells comprising:
a lithium-ion pouch cell; and
an attenuating member affixed to an exterior surface of the lithium-ion pouch cell;
at least one circuitry module configured to control and monitor charging and discharging of the plurality of battery cells;
a flexible printed circuit board assembly (PCBA) comprising:
a plurality of physical connection sections disposed in a grid-like pattern, wherein each of the plurality of battery cells and the at least one circuitry module is physically affixed to the flexible PCBA at a corresponding physical connection section of the plurality of physical connection sections;
a plurality of flexible regions distributed between the physical connection sections disposed in the grid-like pattern, wherein the plurality of flexible regions allows the conformal wearable battery to flex in response to an applied force; and
a plurality of electrical connection pad pairs, wherein each pad pair of the plurality of electrical connection pad pairs is associated with a corresponding physical connection section and is positioned parallel to a corresponding flexible region; and
a sealed flexible housing,
wherein each pad pair of the plurality of electrical connection pad pairs is positioned adjacent and parallel to a corresponding flexible region,
wherein a first pair of electrically conductive elements of a first battery cell is electrically connected to a first electrical connection pad pair via a pair of cutouts and a second pair of electrically conductive elements of a second battery cell is electrically connected to adjacent pads of a second electrical connection pad pair around an edge of the flexible PCBA,
wherein the flexible PCBA is disposed within an interior cavity of the sealed flexible housing, and
wherein the flexible PCBA is in a folded configuration.

### Claim 11 (depends on 10)

The conformal wearable battery of claim 10, wherein each of the plurality of battery cells is physically attached to a first side of the flexible PCBA and each of the plurality of battery cells is electrically connected to the flexible PCBA on a second side of the flexible PCBA, the second side being opposite the first side.

### Claim 12 (depends on 10)

The conformal wearable battery of claim 10, wherein the flexible PCBA comprises a first plurality of electrical connections each connecting a cathode of a corresponding battery cell of the plurality of battery cells and second plurality of electrical connections each connecting an anode of the corresponding battery cell of the plurality of battery cells to electrical conductors of the flexible printed circuit board assembly.

### Claim 13 (depends on 10)

The conformal wearable battery of claim 10, wherein the plurality of battery cells and the at least one circuitry module, when affixed to the flexible PCBA, comprises a matrix of physical components.

### Claim 14 (depends on 10)

The conformal wearable battery of claim 10, wherein the conformal wearable battery comprises at least one connector configured to provide an electrical power connection from internal circuitry of the conformal wearable battery to an external device to be powered.

### Claim 15 (depends on 10)

The conformal wearable battery of claim 10, wherein a bend axis comprises a center of the grid-like pattern of the physical connection sections when the flexible PCBA is unfolded.

### Claim 16 (depends on 10)

The conformal wearable battery of claim 10, wherein each of the plurality of battery cells is physically attached to a first side of the flexible PCBA.

### Claim 17 (depends on 10)

The conformal wearable battery of claim 10,
wherein the plurality of battery cells is disposed on an outside surface of the flexible PCBA, when the flexible PCBA is in a folded configuration, and
wherein the plurality of battery cells is arranged in a three-dimensional grid pattern.

### Claim 18 (depends on 14)

The conformal wearable battery of claim 14, wherein the plurality of battery cells, the at least one connector, and the at least one circuitry module, when affixed to the flexible PCBA, comprises a matrix of physical components.

### Claim 19 (depends on 10)

The conformal wearable battery of claim 10, wherein the sealed flexible housing comprises:
a first shell formed from a first member having a first plurality of rigid regions and a second member that has a first flexible region located between a first rigid region and a second rigid region of the first plurality of rigid regions, and wherein the first shell includes a front wall with an outward facing surface formed from outward facing surfaces of the first plurality of rigid regions and an outward facing surface of the second member, wherein each rigid region of the first plurality of rigid regions is connected to an adjacent rigid region, by a channel on the first member; and
a second shell attached to the first shell, wherein the second shell includes a third member having a second plurality of rigid regions and a fourth member that has a second flexible region located between a first rigid region and a second rigid region of the second plurality of rigid regions, and wherein the second shell has an outward facing surface formed from outward facing surfaces of the second plurality of rigid regions and an outward facing surface of the second member,
wherein the first member is formed as a unitary member formed from a first material and the second member is joined to the first member,
wherein the second member is formed from a second material and wherein a first hardness of the first material is greater than a second hardness of the second material, and
wherein the first shell connects to the second shell to form an interior cavity that receives the plurality of battery cells.