1s2p battery pack for fast charge application-layered structure with PCM pouches and compressible foam for swelling absorption

A method of manufacturing battery pack, said method comprising:

• placing at least two rechargeable battery cell in a first housing part of a housing;
• placing at least one phase change material (PCM) pouch in contact with the at least two rechargeable battery cells within the first housing part, including:
• placing a first PCM pouch between and in contact with the two rechargeable battery cells, one on each side of the first PCM pouch;
• and
• placing a second PCM pouch in contact with one of the rechargeable battery cells and on an opposite side of the first PCM pouch;
• electrically connecting electrical conductors with the at least two rechargeable battery cells to enable electrical power to be conducted to and from the at least two rechargeable battery cells;
• positioning a rigid-flex printed circuit board (PCB) including a first PCB and a second PCB connected via a flexible electrical connector;
• positioning the first PCB on an opposite side of a second of the rechargeable battery cells from the first PCM pouch;
• positioning the second PCB of the rigid-flex PCB extending toward and centrally aligned between the rechargeable battery cells;
• and
• connecting a second housing part of the housing to the first housing part, thereby enclosing the at least two rechargeable battery cells and the at least one PCM pouch in the housing formed by the first and second housing parts.

A mobile device, comprising:

• electronics including:
• a processor configured to control the mobile device;
• and
• electrical power electronics configured to output electrical power;
• and
• a battery pack electronically coupled to the electronics to supply electrical power thereto, and configured with:
• a housing;
• at least two rechargeable battery cells;
• at least one phase change material (PCM) pouch in contact with the at least two rechargeable battery cells to absorb heat produced thereby, the at least one PCM pouch including:
• a first PCM pouch disposed between the at least two rechargeable battery cells, one on each side of the first PCM pouch;
• and
• a second PCM pouch disposed on an opposite side of the first PCM pouch;
• a rigid-flex printed circuit board (PCB) including a first PCB in electrical communication with a second PCB via flexible electrical connector, wherein:
• the first PCB is positioned on an opposite side of a second of the rechargeable battery cells from the first PCM pouch;
• and
• the second PCB is extended toward and centrally aligned between opposing walls of the at least two rechargeable battery cells;
• and
• electrical conductors in electrical communication with the power electronics and the at least two rechargeable battery cells, and configured to conduct electrical power to and from the at least two rechargeable battery cells,
• wherein the at least two rechargeable battery cells, the at least one PCM pouch, and the rigid-flex PCB are enclosed within the housing.