Battery overmolding
AssigneeNIKE, Inc.
InventorsMartine Stillman, Dane Weitmann
Life of this patent
Estimating the term…
Abstract
A portable electronic device commonly includes one or more batteries. Further, a portable electronic device may be manufactured using one or more overmolding techniques to achieve certain aesthetic and/or mechanical characteristics. Batteries within the portable electronic device may be overmolded by using a covering, wherein the covering includes a protective layer such that the batteries are not exposed to the high temperatures and high pressures associated with an overmolding process which may be in excess of temperature and pressure thresholds associated with the batteries.
Claims20
An athletic performance monitoring device comprising:
- a structural frame for the device;
- an electronic component supported by the structural frame and configured for at least one of collecting performance data and displaying information to a user;
- a thermoplastic overmolded material connected to and supported by the structural frame, the overmolded material forming at least a portion of an outer casing structure of the device and at least partially encasing the electronic component;
- a battery connected to the electronic component and configured for supplying power to the electronic component;
- and
- an epoxy layer at least partially surrounding the battery, the epoxy layer having an inner epoxy layer surface and an outer epoxy layer surface, wherein the inner epoxy layer surface is configured to contact an outer surface of the battery, and the outer epoxy layer surface at least partially surrounded by and contacted by the overmolded material, and wherein the epoxy layer is configured to resist transmission of temperature and pressure to the battery during an overmolding process.
A battery assembly, comprising:
- a battery;
- a wired connection connected to the battery and extending from the battery;
- and
- a polymer coating at least partially surrounding the battery, such that an inner surface of the polymer coating covers and contacts a majority of an outer surface of the battery,
- wherein the wired connection extends through the polymer coating, such that the wired connection is accessible and connectable to an electronic component from an exterior of the polymer coating, and
- wherein the polymer coating is configured to resist transmission of temperature and pressure to the battery during an overmolding process.
A method comprising:
- coating at least a portion of an outer surface of a battery with an epoxy resin;
- curing the epoxy resin to form an epoxy layer at least partially surrounding the battery, with an inner surface in contact with the outer surface of the battery, to form a coated battery assembly;
- and
- injection molding a flowable material around at least a portion of the coated battery assembly, wherein the epoxy layer resists transmission of temperature and pressure of the injection molding to the outer surface of the battery, wherein the flowable material solidifies to form an overmolded material at least partially surrounding the coated battery assembly.
An overmolded assembly, comprising:
- an electronic circuit;
- a battery connected to the electronic circuit and configured for supplying power to the electronic circuit;
- an epoxy coating, at least partially coating the battery, wherein the epoxy coating is configured to resist transmission of temperature and pressure to the battery during an overmolding process, wherein the epoxy coating has an inner surface and an outer surface, and wherein the inner surface at least partially coats the electronic circuit;
- and
- an overmolded thermoplastic elastomer layer at least partially surrounding the electronic circuit and the battery, wherein the outer surface of the epoxy coating is at least partially surrounded by and contacted by the overmolded thermoplastic elastomer layer.
Dependencies are inferred from the claim text.