GB2562046A - Flexible substrate battery holder - Google Patents

Flexible substrate battery holder Download PDF

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Publication number
GB2562046A
GB2562046A GB1706917.0A GB201706917A GB2562046A GB 2562046 A GB2562046 A GB 2562046A GB 201706917 A GB201706917 A GB 201706917A GB 2562046 A GB2562046 A GB 2562046A
Authority
GB
United Kingdom
Prior art keywords
battery
flexible substrate
side wall
electrical contact
contact layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1706917.0A
Other versions
GB201706917D0 (en
Inventor
Ali Moazzam
Singh Bhuie Manpreet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saralon GmbH
Original Assignee
Saralon GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saralon GmbH filed Critical Saralon GmbH
Priority to GB1706917.0A priority Critical patent/GB2562046A/en
Publication of GB201706917D0 publication Critical patent/GB201706917D0/en
Priority to PCT/EP2018/025128 priority patent/WO2018202331A1/en
Publication of GB2562046A publication Critical patent/GB2562046A/en
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/18—Printed circuits structurally associated with non-printed electric components
    • H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/216—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for button or coin cells
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/0277—Bendability or stretchability details
    • H05K1/028—Bending or folding regions of flexible printed circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/0393—Flexible materials
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/11—Printed elements for providing electric connections to or between printed circuits
    • H05K1/118—Printed elements for providing electric connections to or between printed circuits specially for flexible printed circuits, e.g. using folded portions
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/05—Flexible printed circuits [FPCs]
    • H05K2201/056—Folded around rigid support or component
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H05K2201/09009—Substrate related
    • H05K2201/091—Locally and permanently deformed areas including dielectric material
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007—Types of components
    • H05K2201/10037—Printed or non-printed battery
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

A battery holder 100 made of a flexible substrate 120, for holding at least one battery 110, where a first part 121 of the flexible substrate is folded over a second part 122 of the flexible substrate at a folding line 131, and an adhesive layer 140 is provided to fix a first portion of the substrate onto a second part and hence to create a housing. The housing includes at least one opening 155 through which the battery is inserted and removed. A first and a second electrical contact layer 160, 170, are each provided on the walls. A first and a second conducting layer 161, 171, are provided on the flexible substrate to electrically connect the first electrical contact layer and the second contact layer respectively. The battery holder may hold two batteries in series configuration. The electrical contact layers and the conducting layers may be printed in conducting ink. There may be means to hold the battery firmly inside the housing. There is an independent claim for a method of producing said battery holder.

Description

(54) Title of the Invention: Flexible substrate battery holder
Abstract Title: Flexible battery holder with opening to remove and insert a battery (57) A battery holder 100 made of a flexible substrate 120, for holding at least one battery 110, where a first part 121 of the flexible substrate is folded over a second part 122 of the flexible substrate at a folding line 131, and an adhesive layer 140 is provided to fix a first portion of the substrate onto a second part and hence to create a housing. The housing includes at least one opening 155 through which the battery is inserted and removed. A first and a second electrical contact layer 160, 170, are each provided on the walls. A first and a second conducting layer 161, 171, are provided on the flexible substrate to electrically connect the first electrical contact layer and the second contact layer respectively. The battery holder may hold two batteries in series configuration. The electrical contact layers and the conducting layers may be printed in conducting ink. There may be means to hold the battery firmly inside the housing. There is an independent claim for a method of producing said battery holder.
100 .
i2i la I7l 161
120 uo
122a
111 110 112
Figure GB2562046A_D0001
l 3 i 151 122c 150
122
154
122b
Fig. 1A /9
Figure GB2562046A_D0002
Figure GB2562046A_D0003
Fig. IB o CM
Figure GB2562046A_D0004
Fig. 1C
2/9
Figure GB2562046A_D0005
Fig- 2A
Figure GB2562046A_D0006
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Fig. 2B
3/9
Figure GB2562046A_D0007
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Figure GB2562046A_D0008
w—, ' '’I TX
Fig. 3B
4/9
Figure GB2562046A_D0009
Fig. 5
5/9
Figure GB2562046A_D0010
Figure GB2562046A_D0011
Fig. 6C
Figure GB2562046A_D0012
Fig. 6D
6/9
Figure GB2562046A_D0013
Fig. 6F
Figure GB2562046A_D0014
Fig. 6G
7/9
710: Printing electrical contact layers (660, 670) and conducting layers (661, 671) on a flexible substrate (620) by using conducting ink.
Figure GB2562046A_D0015
720: Solidifying the printed layers (660, 670, 661, 671).
Figure GB2562046A_D0016
730: Providing folding lines (631, 632, 633, 634) on the flexible substrate 620.
Figure GB2562046A_D0017
740: Providing an adhesive layer 640 on the flexible substrate 620.
Figure GB2562046A_D0018
750: Folding a first part 621 of the flexible substrate 620 over a second part 622 of the flexible substrate 620 at a first folding line 631.
Figure GB2562046A_D0019
760: Fixing a first portion 621a of the first part 621 over the second part 622 through the adhesive layer 640 and hence creating a housing 650 to hold the battery 610.
Fig- 7
8/9
Figure GB2562046A_D0020
Fig. 8B
9/9
Figure GB2562046A_D0021
Fig. 9A
Figure GB2562046A_D0022
QCA 7VV QCl ' \ f 922c '921c T921b 921a
Figure GB2562046A_D0023
Figure GB2562046A_D0024
Figure GB2562046A_D0025
Figure GB2562046A_D0026
Figure GB2562046A_D0027
Fig. 9B
-1TITLE
Flexible substrate battery holder
CROSS-RELATION TO OTHER APPLICATIONS [0001] None
FIELD OF THE INVENTION [0002] The present disclosure relates to a battery holder made of a flexible substrate.
BACKGROUND OF THE INVENTION [0003] Electronics on flexible substrates are becoming increasingly popular and this field is termed as flexible electronics. In flexible electronics, conducting traces are printed on a plastic or paper substrate and different electronic components are fixed on these conducting traces. In some cases, first a printed circuit board is prepared with different electronic components on one side of the PCB and other side of the PCB comprises contact pads, which are then fixed on conducting traces. A major challenge in flexible electronics is the incorporation of a battery holder. Most of the coin cell, button cell, AA, AAA, 9-volt etc. battery holders are bulky and made of rigid materials e.g. strong plastic and metal. This is a complex and difficult process to fix a battery on a flexible substrate. Therefore, there is a need to have a battery holder that is compact and is made of a flexible substrate. There have been some attempts made to create a battery holder based on flexible substrate, as disclosed in US Patent publication no. US 2014/0147719 Al and US 2014/0199572 A. But in both these cases, the battery is required to be inserted into the flexible battery holder during the preparation of the holder itself. The battery can’t be removed and a new battery can’t be inserted into these battery holders.
SUMMARY OF THE INVENTION [0004] The present invention relates to a battery holder for holding at least one battery. The battery holder is made of a flexible substrate. A first part of the flexible substrate is folded over a second part of the flexible substrate at the first folding line. An adhesive layer is provided on the flexible substrate to secure and fix a first portion of the first part onto the second part and hence creating a housing. The said housing is defined by a first side wall, a second side wall, a top wall, a bottom wall and comprises of at least one opening. At least one opening is
-1perpendicular to the walls. The at least one battery is inserted into and removed from the housing through the at least one opening. A first electrical contact layer is provided on at least one of the first side wall, the second side wall and the top wall. The first electrical contact layer electrically engages with a first terminal of the at least one battery. A second electrical contact layer is provided on at least one of the first side wall, the second side wall and the bottom wall. The second electrical contact layer electrically engages with a second terminal of the at least one battery. A first conducting layer is provided on the flexible substrate and electrically connected to the first electrical contact layer. A second conducting layer is provided on the flexible substrate and electrically connected to the second electrical contact layer.
BRIEF DESCRIPTION OF THE DRAWINGS [0005] FIG. 1A is a cross sectional view of a battery holder with a battery inside it, in accordance with an aspect of the present invention.
[0006] FIG. IB is a cross sectional view of a battery holder with a battery outside the battery holder, in accordance with an aspect of the present invention.
[0007] FIG. 1C is a top view of an unfolded battery holder, in accordance with an aspect of the present invention.
[0008] FIG. 2A is a cross sectional view of a battery holder with a battery inside it, in accordance with another aspect of the present invention.
[0009] FIG. 2B is a top view of an unfolded battery holder, in accordance with an aspect of the present invention.
[00010] FIG. 3 A is a cross sectional view of a battery holder with two batteries inside it, in accordance with an aspect of the present invention.
[00011] FIG. 3B is a cross sectional view of a battery holder with two batteries inside it, in accordance with another aspect of the present invention.
[00012] FIG. 4 is a cross sectional view of a battery holder with a battery inside it, in accordance with another aspect of the present invention.
-3[00013] FIG. 5 is a cross sectional view of a battery holder with a battery inside it, in accordance with another aspect of the present invention.
[00014] FIG. 6A is a top view of a flexible substrate.
[00015] FIG. 6B is a top view of a flexible substrate with conducting layers and electrical contact layers.
[00016] FIG. 6C is a top view of a flexible substrate with a plurality of folding lines.
[00017] FIG. 6D is a top view of a flexible substrate with an adhesive layer.
[00018] FIG. 6E is a cross sectional view of a folded flexible substrate.
[00019] FIG. 6F is a cross sectional view of an erected battery holder.
[00020] FIG. 6G is a cross sectional view of a battery holder with a battery inside it.
[00021] FIG. 7 is a flow chart showing a manufacturing process to produce the battery holder according to one exemplary embodiment of the present disclosure.
[00022] FIG. 8A is a cross sectional view of a battery holder with a battery inside it, in accordance with another aspect of the present invention.
[00023] FIG. 8B is a top view of an unfolded battery holder, in accordance with an aspect of the present invention.
[00024] FIG. 9A is a cross sectional view of a battery holder with a battery inside it, in accordance with another aspect of the present invention.
[00025] FIG. 9B is a top view of an unfolded battery holder, in accordance with an aspect of the present invention.
-4DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [00026] The invention will now be described in detail. Drawings and examples are provided for better illustration of the invention. It will be understood that the embodiments and aspects of the invention described herein are only examples and do not limit the protector’s scope of the claims in any way. The invention is defined by the claims and their equivalents. It will be understood that features of one aspect or embodiment of the invention can be combined with the feature of a different aspect or aspects and/or embodiments of the invention.
[00027] The present invention is about a battery holder made of a flexible substrate. Fig. 1A shows a cross sectional view of a battery holder 100 with a battery 110. The battery holder 100 is made of a flexible substrate 120. In a non-limiting aspect, the flexible substrate 120 is paper, plastic or a laminate of paper and plastic etc. The thickness of the flexible substrate 120 can be in the range of 50 micrometers to 800 micrometers. The flexible substrate 120 can be a part of a package which comprises electronic components. For example, a package made of paper is printed with silver ink. On the paper is fixed SMD LED. The electrical power to the LEDs comes from a coin cell battery kept in the same paper package, by using the battery holder made of the same paper. The battery 110 can be a coin cell battery or a button cell battery. The flexible substrate 120 comprises at least two parts, a first part 121 of the flexible substrate 120 is folded over a second part 122 of the flexible substrate 120 at the first folding line 131. An adhesive layer 140 provided on the flexible substrate 120 to fix a first portion 121a of the first part 121 onto a first portion 122a of the second part 122 and hence creating a housing 150. The housing 150 is defined by a first side wall 151, a second side wall 152, a top wall 153, a bottom wall 154 and one or two openings 155. The opening 155 is perpendicular to the walls 151, 152, 153 and 154. The battery 110 is inserted into and removed from the housing 150 through the at least one opening 155. A second portion 121b of the first part 121 makes the second side wall 152, a third portion 121c of the first part 121 makes the top wall 153, a second portion 122b of the second part 122 makes the bottom wall 154 and a third portion 122c of the second part 122 makes the first side wall 151. A first electrical contact layer 160 is provided on the first side wall 151, the second side wall 152 and the top wall 153. The first electrical contact layer 160 can be a printed conductive silver layer on the flexible substrate 120. The first electrical contact layer 160 electrically engages with a first terminal 111 of the battery 110. A second electrical contact layer 170 is provided on the bottom wall 154. The second electrical contact layer 170 can be a printed conductive silver layer on the flexible substrate 120. The second electrical
-5contact layer 170 electrically engages with a second terminal 112 of the battery 110. The second terminal 112 of the battery 110 is opposite to the first terminal 111. A first conducting layer 161 and a second conducting layer 171 are provided on the flexible substrate 120 to electrically connect the first electrical contact layer 160 and the second electrical contact layer 170, respectively. The first conducting layer 161 and the second conducting layer 171 can be printed conducting silver layer on the flexible substrate 120. The purpose of the first conducting layer 161 and the second conducting layer is to bring the two electrical contact terminals 111 and 112 of the battery 110 outside of the housing 150.
[00028] Fig. IB shows a cross sectional view of a battery holder 100 without the battery 110. Here, the battery 110 is outside of the housing 150. Fig. 1C shows a top view of an unfolded battery holder. Folding of the flexible substrate 120 is done at the first folding line 131. When the flexible substrate 120 is folded at the first folding line 131, the first portion 121a of the first part 121 of the flexible substrate 120 comes over the adhesive layer 140. The adhesive layer 140 is provided on the first portion 122a of the second part 122 of the flexible substrate 120.
[00029] Fig. 2A shows a cross sectional view of another embodiment of the battery holder 200 made of a flexible substrate 220. The flexible substrate 220 comprises at least two parts, a first part 221 of the flexible substrate 220 is folded over a second part 222 of the flexible substrate 220 at the first folding line 231. An adhesive layer 240 is provided between a first portion 221 a of a first part 221 of the flexible substrate 220 and a second portion 222b of a second part 222 of the flexible substrate 220. A housing 250 is created by folding and fixing the flexible substrate 220. The housing 250 is defined by a first side wall 251, a second side wall 252, a top wall 253, a bottom wall 254 and one or two openings 255. The opening 255 is perpendicular to the walls 251, 252, 253 and 254. A battery 210 is inserted into and removed from the housing 250 through the at least one opening 255. The first portion 221a of the first part 221 makes the bottom wall 254, a second portion 221b of the first part 221 makes the second side wall 252, a third portion 221c of the first part 221 makes the top wall 253 and a third portion 222c of the second part 222 makes the first side wall 251. A first electrical contact layer 260 is provided on the first side wall 251, the second side wall 252 and the top wall 253. The first electrical contact layer 260 electrically engages with a first terminal 211 of the battery 210. A second electrical contact layer 270 is provided on the bottom wall 254. The second electrical contact layer 270 electrically engages with a second terminal 212 of the battery 210. A first conducting layer 261 and a second conducting layer 271 are provided on the flexible substrate 220 to electrically
-6connect the first electrical contact layer 260 and the second electrical contact layer 270, respectively. Fig. 2B shows a top view of an unfolded battery holder. Folding of the flexible substrate 220 is done at the first folding line 231. When the flexible substrate 220 is folded at the first folding line 231, the first portion 221a of the first part 221 of the flexible substrate 220 comes over the adhesive layer 240. The adhesive layer 240 is provided on the second portion 222b of the second part 222 of the flexible substrate 220.
[00030] Fig. 3A shows a cross sectional view of a battery holder 300 with a first battery 315 and a second battery 310. The battery holder 300 is made of a flexible substrate 320. The flexible substrate 320 comprises at least two parts, a first part 321 of the flexible substrate 320 is folded over a second part 322 of the flexible substrate 320 at the first folding line 331. An adhesive layer 340 provided on the flexible substrate 320 to fix a first portion 321a of the first part 321 onto a first portion 322a of the second part 322 and hence to create a housing 350. The housing 350 is defined by a first sidewall 351, a second sidewall 352, atop wall 353, a bottom wall 354 and one or two openings 355. A second portion 321b of the first part 321 makes the second side wall 352, a third portion 321c of the first part 321 makes the top wall 353, a second portion 322b of the second part 322 makes the bottom wall 354 and a third portion 322c of the second part 322 makes the first side wall 351. A first electrical contact layer 360 is provided on the first side wall 351, the second side wall 352 and the top wall 353. The first electrical contact layer 360 electrically engages with a first terminal 316 of the first battery 315. The second terminal 317 of the first battery 315 is in contact with a first terminal 311 of a second battery 310. A second electrical contact layer 370 is provided on the bottom wall 354. The second electrical contact layer 370 electrically engages with a second terminal 312 of the second battery 310. The batteries 310 and 315 are connected in a series connection. A first conducting layer 361 and a second conducting layer 371 are provided on the flexible substrate 320 to electrically connect the first electrical contact layer 360 and the second electrical contact layer 370, respectively.
[00031] Fig. 3B shows a cross sectional view of a battery holder 300 with a first battery 315 and a second battery 310. The battery holder 300 is made of a flexible substrate 320. The flexible substrate 320 comprises at least two parts, a first part 321 of the flexible substrate 320 is folded over a second part 322 of the flexible substrate 320 at the first folding line 331. An adhesive layer 340 provided on the flexible substrate 320 to fix a first portion 321a of the first part 321 onto a first portion 322a of the second part 322 and hence to create a housing 350. The
-Ί housing 350 is defined by a first sidewall 351, a second sidewall 352, atop wall 353, a bottom wall 354 and one or two openings 355. A second portion 321b of the first part 321 makes the second side wall 352, a third portion 321c of the first part 321 makes the top wall 353, a second portion 322b of the second part 322 makes the bottom wall 354 and a third portion 322c of the second part 322 makes the first side wall 351. A first electrical contact layer 360 is provided on the first side wall 351 and the bottom wall 354. The first electrical contact layer 360 electrically engages with a first terminal 311 of the second battery 310. The second terminal 312 of the second battery 310 is in contact with a first terminal 316 of the first battery 315. A second electrical contact layer 370 is provided on the top wall 353. The second electrical contact layer 370 electrically engages with a second terminal 317 of the first battery 315. The batteries 310 and 315 are connected in a series connection. A first conducting layer 361 and a second conducting layer 371 are provided on the flexible substrate 320 to electrically connect the first electrical contact layer 360 and the second electrical contact layer 370, respectively.
[00032] Fig. 4 shows a cross sectional view of a battery holder 400 with a battery 410. The battery holder 400 is made of a flexible substrate 420. The flexible substrate 420 comprises at least two parts, a first part 421 of the flexible substrate 420 is folded over a second part 422 of the flexible substrate 420 at the first folding line 431. An adhesive layer 440 is provided on the flexible substrate 420 to fix a first portion 421a of the first part 421 onto a first portion 422a of the second part 422 and hence to create a housing 450. The housing 450 is defined by a first side wall 451, a second side wall 452, atop wall 453, a bottom wall 454 and one or two openings 455. A second portion 421b of the first part 421 makes the second side wall 452, a third portion 421c of the first part 421 makes the top wall 453, a second portion 422b of the second part 422 makes the bottom wall 454 and a third portion 422c of the second part 422 makes the first side wall 451. An area 481 of the top wall 453 is embossed inwards and another area 480 of the bottom wall 454 is embossed inwards in order to keep the battery 410 tightly in the housing 450. The embossing of the flexible substrate 420 can be done on one or more areas. The embossing can lie on at least one of the four walls. A first electrical contact layer 460 is provided on the first side wall 451, the second side wall 452 and the top wall 453. The first electrical contact layer 460 electrically engages with a first terminal 411 of the battery 410. A second electrical contact layer 470 is provided on the bottom wall 454. The second electrical contact layer 470 electrically engages with a second terminal 412 of the battery 410. A first conducting layer 461 and a second conducting layer 471 are provided on the flexible substrate
-8420 to electrically connect the first electrical contact layer 460 and the second electrical contact layer 470, respectively.
[00033] Fig. 5 shows a cross sectional view of a battery holder 500 with a battery 510. The battery holder 500 is made of a flexible substrate 520. The flexible substrate 520 comprises at least two parts, a first part 521 of the flexible substrate 520 is folded over a second part 522 of the flexible substrate 520 at the first folding line- 531. An adhesive layer 540 is provided on the flexible substrate 520 to fix a first portion 521a of the first part 521 onto a first portion 522a of the second part 522 and hence to create a housing 550. The housing 550 is defined by a first side wall 551, a second side wall 552, atop wall 553, a bottom wall 554 and one or two openings 555. A second portion 521b of the first part 521 makes the second side wall 552, a third portion 521c of the first part 521 makes the top wall 553, a second portion 522b of the second part 522 makes the bottom wall 554 and a third portion 522c of the second part 522 makes the first side wall 551. A cut 590 is provided on the first side wall 551. The purpose of the cut 590 is to keep the battery 510 held tightly inside the housing 550. The cut can be provided on at least one of the four walls. A first electrical contact layer 560 is provided on the first side wall 551, the second side wall 552 and the top wall 553. The first electrical contact layer 560 electrically engages with a first terminal 511 of the battery 510. A second electrical contact layer 570 is provided on the bottom wall 554. The second electrical contact layer 570 electrically engages with a second terminal 512 of the battery 510. A first conducting layer 561 and a second conducting layer 571 are provided on the flexible substrate 520 to electrically connect the first electrical contact layer 560 and the second electrical contact layer 570, respectively.
[00034] Fig. 6 shows in detail how the battery holder 100 is produced. A flexible substrate 620 is provided, as shown in Fig. 6A. The shape of the flexible substrate 620 shown in Fig. 6A is just an example. It does not limit the scope of the invention. A first electrical contact layer 660, a second electrical contact layer 670, a first conducting layer 661 and a second conducting layer 671 are printed on a flexible substrate 620 by using a conductive ink e.g. silver ink, copper ink carbon ink etc., as shown in Fig. 6B. After printing the layers, a curing and or drying step is needed to solidify the printed ink. The first conducting layer 661 is connected to the first electrical contact layer 660 and the second conducting layer671 is connected to the second electrical contact layer 670, as shown in Fig. 6B. After that a first folding line 631, a second folding line 632, a third folding line 633 and a fourth folding line 634 are provided on the flexible substrate 620 as shown in Fig. 6C. In a non-limiting aspect, the folding lines can be
-9provided by creasing the flexible substrate 620. In another non-limiting aspect, the folding lines can be provided by kiss-cutting the flexible substrate 620. In another non-limiting aspect, the folding lines can be provided by perforating the flexible substrate 620. The folding lines are provided such that the first folding line 631 separates the flexible substrate 620 into a first part 621 and a second part 622. The area between the first folding line 631 and the second folding line 632 is named as the third potion 621c of the first part 621 and it makes a top wall 653 of a housing 650. The area between the second folding line 632 and the third folding line 633 is named as the second potion 621b of the first part 621 and it makes a second side wall 652 of a housing 650. The area between the first folding line 631 and the fourth folding line 634 is named as the third potion 622c of the second part 622 and it makes a first wall 651 of the housing 650. An adhesive layer 640 is provided on a first portion 621a of the first part 621, as shown in the Fig. 6D. After that the first part 621 is folded over the second part 622 at the first folding line 631 and the adhesive layer 640 is fixed on a first portion 622a of the second part 622, as shown in Fig. 6E. In the next step, the housing 650 is erected, as shown in the Fig. 6F, which creates two openings 655. The battery 610 is inserted into the housing 650 through the openings 655, as shown in Fig. 6G. A first terminal 611 of the battery 610 is touching the first electrical contact layer 660 and the a second terminal 612 of the battery 610 is touching the second electrical contact layer 670.
[00035] The battery holder 600 can be produced according to the following exemplary process, as illustrated in Fig. 7:
[00036] In the step 710, a first electrical contact layer 660, a second electrical contact layer 670, a first conducting layer 661 and a second conducting layer 671 are printed on a flexible substrate 620 by using a conductive ink.
[00037] In the step 720, the printed layers are solidified by a drying and/or a curing step.
[00038] In the step 730, a first folding line 631, a second folding line 632, a third folding line 633 and a fourth folding line 634 are provided on the flexible substrate 620.
[00039] In the step 740, an adhesive layer 640 is provided on the flexible substrate 620.
-10[00040] In the step 750, a first part 621of the flexible substrate 620 is folded over a second part 622 of the flexible substrate 620 at the first folding line 631.
[00041] In the step 760, a first portion 621a of the first part 621 is fixed onto the second part 622 through the adhesive layer 640 and hence creating a housing 650. The housing 650 is defined by a first side wall 651, a second side wall 652, a top wall 653, a bottom wall 654 and at least one opening 655. The at least one battery 610 can be inserted into and removed from the housing 650 through the at least one opening 655. The first electrical contact layer 660 lies on at least one of the first side wall 651, the second side wall 652, the bottom wall 654 and the top wall 653 to electrically engages with a first terminal 61 lof the at least one battery 610. The second electrical contact layer 670 lies on at least one of the first side wall 651, the second side wall 652, the top wall 653 and the bottom wall 654 to electrically engages with a second terminal 612 of the at least one battery 610.
[00042] Fig. 8A shows a cross sectional view of a battery holder 800 with a battery 810. The battery 810 comprises a first terminal 811 and a second terminal 812 opposite to each other as in AAA, AA and A batteries. Other batteries with similar configurations of terminals can also be used here. The battery holder 800 is made of a flexible substrate 820. The flexible substrate
820 comprises at least two parts, a first part 821 of the flexible substrate 820 is folded over a second part 822 of the flexible substrate 820 at the first folding line 831. Fig. 8B shows an unfolded battery' holder 800. An adhesive layer 840 provided on the flexible substrate 820 to fix a first portion 821a of the first part 821 onto a first portion 822a of the second part 822 and hence to create a housing 850. The housing 850 is defined by a first side wall 851, a second side wall 852, a top wall 853, a bottom wall 854 and one or two openings 855. A second portion 821b of the first part 821 makes the second side wall 852, a third portion 821c of the first part
821 makes the top wall 853, a second portion 822b of the second part 822 makes the bottom wall 854 and a third portion 822c of the second part 822 makes the first side wall 851. A first electrical contact layer 860 is provided on the first side wall 851. The first electrical contact layer 860 electrically engages with a first terminal 811 of the battery 810. A second electrical contact layer 870 is provided on the second side wall 852. The second electrical contact layer 870 electrically engages with a second terminal 812 of the battery 810. A first conducting layer 861 and a second conducting layer 871 are provided on the flexible substrate 820 to electrically connect the first electrical contact layer 860 and the second electrical contact layer 870, respectively.
-11[00043] Fig. 9A shows a cross sectional view of a battery holder 900 with a battery 910. The battery 910 comprises a first terminal 911 and a second terminal 812 on the same side of the battery e.g. 9 Volt battery. Other batteries with similar configurations of terminals can also be used here. The battery holder 900 is made of a flexible substrate 920. The flexible substrate
920 comprises at least two parts, a first part 921 of the flexible substrate 920 is folded over a second part 922 of the flexible substrate 920 at the first folding line 931. Fig. 9B shows an unfolded battery' holder 900. An adhesive layer 940 provided on the flexible substrate 920 to fix a first portion 921a of the first part 921 onto a first portion 922a of the second part 922 and hence to create a housing 950. The housing 950 is defined by a first side wall 951, a second side wall 952, a top wall 953, a bottom wall 954 and one or two openings 955. A second portion 921b of the first part 921 makes the second side wall 952, a third portion 921c of the first part
921 makes the top wall 953, a second portion 922b of the second part 922 makes the bottom wall 954 and a third portion 922c of the second part 922 makes the first side wall 951. A first electrical contact layer 960 is provided on the first side wall 951. The first electrical contact layer 960 electrically engages with a first terminal 911 of the battery 910. A second electrical contact layer 970 is provided on the first side wall 951. The second electrical contact layer 970 electrically engages with a second terminal 912 of the battery 910. A first conducting layer 961 and a second conducting layer 971 are provided on the flexible substrate 920 to electrically connect the first electrical contact layer 960 and the second electrical contact layer 970, respectively.

Claims (11)

1. A battery holder (100) for holding at least one battery (110), comprising:
a flexible substrate (120), wherein a first part (121) of the flexible substrate (120) is folded over a second part (122) of the flexible substrate (120) at a first folding line (131);
an adhesive layer (140) provided on the flexible substrate (120) to fix a first portion (121a) of the first part (121) onto the second part (122) and hence to create a housing (150), wherein the housing (150) is defined by a first side wall (151), a second side wall (152), a top wall (153), a bottom wall (154) and at least one opening (155), the at least one opening (155) is perpendiculartothe walls (151, 152, 153, 154), the at least one battery (110) is inserted into and removed from the housing (150) through the at least one opening (155);
a first electrical contact layer (160) provided on at least one of the first side wall (151), the second side wall (152), the top wall (153) and the bottom wall (154), wherein the first electrical contact layer (160) electrically engages with a first terminal (111) of the at least one battery (110);
a second electrical contact layer (170) provided on at least one of the first side wall (151), the second side wall (152), the top wall (153) and the bottom wall (154), wherein the second electrical contact layer (170) electrically engages with a second terminal (112) of the at least one battery (110);
a first conducting layer (161) provided on the flexible substrate (120) and electrically connected to the first electrical contact layer (160); and a second conducting layer (171) provided on the flexible substrate (120) and electrically connected to the second electrical contact layer (170).
2. The battery holder (100) as claimed in claim 1, wherein the first portion (121a) of the first part (121) is fixed onto a first portion (122a) of the second part (122), a second portion (121b) of the first part (121) makes the second side wall (152), a third portion (121c) of the first part (121) makes the top wall (153), a second portion (122b) of the second part (122)
-13makes the bottom wall (154) and a third portion (122c) of the second part (122) makes the first side wall (151).
3. The battery holder (100, 200) as claimed in claim 1, wherein the first portion (221a) of the first part (221) is fixed onto a second portion (222b) of the second part (222), the first portion (221a) of the first part (221) makes the bottom wall (254), a second portion (221b) of the first part (221) makes the second side wall (252), a third portion (221c) of the first part (221) makes the top wall (253) and a third portion (222c) of the second part (222) makes the first side wall (251).
4. The battery holder (100, 300) as claimed in claim 1, wherein the at least one battery (110) comprises two batteries (310, 315) in series configuration.
5. The battery holder (100) as claimed in claim 1, wherein the flexible substrate (120) is selected from the group of paper and plastic.
6. The battery holder (100) as claimed in claim 1, wherein the first electrical contact layer (160), the second electrical contact layer (170), the first conducting layer (161) and the second conducting layer (171) are printed conducting ink.
7. The battery holder (100, 500) as claimed in claim 1, further comprises at least one cut (590) on at least one of the first side wall (551) and the second side wall (552) to tightly hold the at least one battery (510) in the housing (550).
8. The battery holder (100, 400) as claimed in claim 1, further comprises at least one embossed area (480, 481) on at least one of the bottom wall (454) and the top wall (453) to tightly hold the at least one battery (410) in the housing (450).
9. A method of producing a battery holder (600) to hold at least one battery (610), comprising the steps of:
a. printing a first electrical contact layer (660), a second electrical contact layer (670), a first conducting layer (661) and a second conducting layer (671) on a flexible substrate 620) by using a conducting ink, wherein the first conducting layer (661) is connected to
-14the first electrical contact layer (660) and the second conducting layer (671) is connected to the second electrical contact layer (670);
b. solidifying the printed layers (660, 670, 661, 671);
c. providing a first folding line (631), a second folding line (632), a third folding line (633) and a fourth folding line (634) on the flexible substrate (620);
d. providing an adhesive layer (640) on the flexible substrate (620);
e. folding a first part (621) of the flexible substrate (620) over a second part (622) of the flexible substrate (620) at the first folding line (631); and
f. fixing a first portion (621a) of the first part (621) onto the second part (622) through the adhesive layer (640) and hence creating a housing (650), wherein the housing (650) is defined by a first side wall (651), a second side wall (652), a top wall (653), a bottom wall (654) and at least one opening (655), the at least one opening (655) is perpendicular to the walls (651, 652, 653, 654), the at least one battery (610) can be inserted into and removed from the housing (650) through the at least one opening (655), the first electrical contact layer (660) lies on at least one of the first side wall (651), the second side wall (652), the bottom wall (654) and the top wall (653) to electrically engages with a first terminal (611) of the at least one battery (610), the second electrical contact layer (670) lies on at least one of the first side wall (651), the second side wall (652), the top wall (653) and the bottom wall (654) to electrically engage with a second terminal (612) of the at least one battery (610).
10. The method of claim 9, wherein the first portion (621a) of the first part (621) is fixed onto a first portion (622a) of the second part (622), a second portion (621b) of the first part (621) makes the second side wall (652), a third portion (621c) of the first part (621) makes the top wall (653), a second portion (622b) of the second part (622) makes the bottom wall (654) and a third portion (622c) of the second part (622) makes the first side wall (651).
11. The method of claim 9, wherein the first portion (621a) of the first part (621) is fixed onto a second portion (622b) of the second part (622), the first portion (621a) of the first part (621) makes the bottom wall (654), a second portion (621b) of the first part (621) makes the second side wall (652), a third portion (621c) of the first part (621) makes the top wall (653) and a third portion (622c) of the second part (622) makes the first side wall (651).
-1512. The method of claim 9, wherein the folding lines (631, 632, 633, 634) are produced using at least one of the cutting and creasing steps.
Intellectual
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Application No: Claims searched:
GB1706917.0A 2017-05-02 2017-05-02 Flexible substrate battery holder Withdrawn GB2562046A (en)

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GB1706917.0A GB2562046A (en) 2017-05-02 2017-05-02 Flexible substrate battery holder
PCT/EP2018/025128 WO2018202331A1 (en) 2017-05-02 2018-04-25 Flexible substrate battery holder

Applications Claiming Priority (1)

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US11733746B2 (en) * 2019-07-24 2023-08-22 Hewlett-Packard Development Company, L.P. Plates to retain power bricks

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US5637418A (en) * 1996-02-08 1997-06-10 Motorola, Inc. Package for a flat electrochemical device

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US5993248A (en) * 1997-11-20 1999-11-30 Itt Manufacturing Enterprises, Inc. Battery connector
US8460026B2 (en) * 2011-04-25 2013-06-11 Soligic, Inc. Circuit element coupling devices and methods for flexible and other circuits
US9214660B2 (en) * 2011-11-29 2015-12-15 Ethertronics, Inc. Flexible substrate battery jacket
US20140199572A1 (en) * 2013-01-17 2014-07-17 Sensormatic Electronics, LLC Film-based battery holder

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US5637418A (en) * 1996-02-08 1997-06-10 Motorola, Inc. Package for a flat electrochemical device

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