Abstract: A molded housing of a conformal wearable battery (CWB) encloses an electronic component and include an electrically conductive contact component embedded within an exterior wall to conduct electricity between an interior and an exterior of the casing. A flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) is enclosed in a cavity within the molded housing and includes attachment sections for a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. A visco-elastic shock-absorbing member installed between the upper and lower portion of the flexible PCBA when configured in a folded configuration. Each battery cell is joined to the flexible PCBA via a welding process. Each battery cell has a visco-elastic shock-absorbing member attached individually to each battery cell of the plurality of battery cells.

Abstract: In one embodiment, an apparatus for redundant control of active fuses for battery pack safety is provided, comprising a battery; an electrical load coupled to the battery via a fuse capable of being activated by an electrical signal; a sensor configured to sense a short circuit condition at the electrical load and output an analog sensor signal; an analog-to-digital converter configured to sample the analog sensor signal and output a digital sensor signal; a microcontroller configured to detect the short circuit condition at the electrical load based on the digital sensor signal, and, during normal operation, to output a first electrical signal to activate the fuse after detecting the short circuit condition at the electrical load; and an analog circuit configured to operate independently of the microcontroller to receive the analog sensor signal and output a second electrical signal to activate the fuse after receiving the analog sensor signal.

Abstract: A housing of a conformal wearable battery (CWB) encloses a plurality of battery cells arranged in a grid-like pattern and electrically connected to a printed circuit board (PCB). The PCB includes an electrical connection pad that is electrically coupled to a positive terminal of a battery cell of the plurality of battery cells and a positive conductive region receiving electrical energy from one or more of the plurality of battery cells. A redundant trace fuse circuit is formed on the PCB to facilitate electrical connection of the electrical connection pad and the positive conductive region. The redundant trace fuse circuit includes a first fusible link for electrically connecting the first electrical connection pad to the positive conductive region and a second fusible link that is selectively enabled to electrically connect the first electrical connection pad to the positive conductive region when the first fusible link is inoperative.

Abstract: A battery system with a large-format Li-ion battery pack powers attached equipment by discharging battery cells distributed among a plurality of battery packs. A limp home notification is generated from a smart lithium-ion battery pack to one or more application devices using an analog signal. The battery pack may provide broadcast messages over electronic communication lines, that includes state of charge (SoC), fault status, etc. which can be read by one or more application devices to enter limp home mode. In another example, a “fully charged” notification is generated from the smart lithium-ion battery pack to one or more application devices using an analog signal. The end device powered by the battery pack system receives and reacts to the outputted fully charged signal by modifying the state of the circuitry on the end device.

Abstract: A battery system with a large-format Li-ion battery pack powers attached equipment by discharging battery cells distributed among a plurality of battery packs. A limp home notification is generated from a smart lithium-ion battery pack to one or more application devices using an analog signal. The battery pack may provide broadcast messages over electronic communication lines, that includes state of charge (SoC), fault status, etc. which can be read by one or more application devices to enter limp home mode. In another example, a “fully charged” notification is generated from the smart lithium-ion battery pack to one or more application devices using an analog signal. The end device powered by the battery pack system receives and reacts to the outputted fully charged signal by modifying the state of the circuitry on the end device.

Abstract: A battery system with a large-format Li-ion battery pack powers attached equipment by discharging battery cells distributed among a plurality of battery packs. A limp home notification is generated from a smart lithium-ion battery pack to one or more application devices using an analog signal. The battery pack may provide broadcast messages over electronic communication lines, that includes state of charge (SoC), fault status, etc. which can be read by one or more application devices to enter limp home mode. In another example, a “fully charged” notification is generated from the smart lithium-ion battery pack to one or more application devices using an analog signal. The end device powered by the battery pack system receives and reacts to the outputted fully charged signal by modifying the state of the circuitry on the end device.

Abstract: A battery system with a large-format Li-ion battery pack powers attached equipment by discharging battery cells distributed among a plurality of battery packs. A limp home notification is generated from a smart lithium-ion battery pack to one or more application devices using an analog signal. The battery pack may provide broadcast messages over electronic communication lines, that includes state of charge (SoC), fault status, etc. which can be read by one or more application devices to enter limp home mode. In another example, a “fully charged” notification is generated from the smart lithium-ion battery pack to one or more application devices using an analog signal. The end device powered by the battery pack system receives and reacts to the outputted fully charged signal by modifying the state of the circuitry on the end device.

Abstract: A matrix of battery cell modules includes a flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) with a plurality of attachment sections for each of a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. Each battery cell may be joined with a flexible PCB via a welding process. The flexible PCBA is configured to fold along a bend axis so that the flexible PCBA is folded approximately in half. When affixed to the flexible PCBA, the plurality of battery cell modules and a circuitry module form a grid of physical components. When folded, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.

Abstract: A molded housing of a conformal wearable battery (CWB) encloses an electronic component and include an electrically conductive contact component embedded within an exterior wall to conduct electricity between an interior and an exterior of the casing. A flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) is enclosed in a cavity within the molded housing and includes attachment sections for a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. A visco-elastic shock-absorbing member installed between the upper and lower portion of the flexible PCBA when configured in a folded configuration. Each battery cell is joined to the flexible PCBA via a welding process. Each battery cell has a visco-elastic shock-absorbing member attached individually to each battery cell of the plurality of battery cells.

Abstract: A matrix of battery cell modules includes a flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) with a plurality of attachment sections for each of a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. Each battery cell may be joined with a flexible PCB via a welding process. The flexible PCBA is configured to fold along a bend axis so that the flexible PCBA is folded approximately in half. When affixed to the flexible PCBA, the plurality of battery cell modules and a circuitry module form a grid of physical components. When folded, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.

Abstract: A housing of a conformal wearable battery (CWB) encloses a plurality of battery cells arranged in a grid-like pattern and electrically connected to a printed circuit board (PCB). The PCB includes an electrical connection pad that is electrically coupled to a positive terminal of a battery cell of the plurality of battery cells and a positive conductive region receiving electrical energy from one or more of the plurality of battery cells. A redundant trace fuse circuit is formed on the PCB to facilitate electrical connection of the electrical connection pad and the positive conductive region. The redundant trace fuse circuit includes a first fusible link for electrically connecting the first electrical connection pad to the positive conductive region and a second fusible link that is selectively enabled to electrically connect the first electrical connection pad to the positive conductive region when the first fusible link is inoperative.

Abstract: A flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CBB) includes attachment sections for a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. The flexible PCBA is configured to fold along a bend axis so that the flexible PCBA is folded approximately in half. To reduce mechanical stresses placed on the flexible PCBA when folding the flexible PCBA along the bend axis, the flexible PCBA includes a plurality of cut-outs dispersed along the bend axis and parallel to adjacent battery cells. The CWB is configured to flex during use. The flexible PCBA includes a plurality of cut-outs disposed perpendicular to the bend axis, between adjacent rows of battery cells, and on the bend axis to relieve mechanical stresses applied to a bent portion of the flexible PCBA when the CWB is flexed during use.

Abstract: A matrix of battery cell modules includes a flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) with a plurality of attachment sections for each of a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. Each battery cell may be joined with a flexible PCB via a welding process. The flexible PCBA is configured to fold along a bend axis so that the flexible PCBA is folded approximately in half. When affixed to the flexible PCBA, the plurality of battery cell modules and a circuitry module form a grid of physical components. When folded, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.