Abstract: Battery assemblies, as well as methods and processes for forming same. A battery assembly can include a first tab electrically connected to a first terminal of a battery and a second tab electrically connected to a second terminal of the battery. A battery assembly can also include a first conductive path (aka first section) having a first end, and a second conductive path (aka second section) having a second end. Another end of the first conductive path can be coupled an electronic device, such as an electric circuit. Another end of the second conductive path can be coupled to the electronic device as well. A space separates the first and second ends; the space formed by removing at least one portion of a U-shaped conductive path. The first conductive path and the first battery tab are connected. The second conductive path and the second battery tab are also connected.

Abstract: Methods and systems for detecting and compensating for expansion of rechargeable batteries over time. An expansion detector may be coupled to or positioned proximate a rechargeable battery to monitor for expansion thereof. After expansion exceeding a selected threshold is detected, the expansion detector may report the expansion to an associated processing unit. The processing unit may undertake to arrest further rechargeable battery expansion by modifying or changing one or more characteristics of charging and/or discharging circuitry coupled to the rechargeable battery. For example, the processing unit may charge the rechargeable battery at a lower rate or with reduced voltage after detecting expansion.

Abstract: Examples are disclosed herein that relate to curved batteries. One example provides a battery comprising an anode arranged on an anode substrate, a cathode arranged on a cathode substrate, the anode substrate being curved at a first curvature and the cathode substrate being curved at a second curvature, and a separator between the anode and the cathode. A thickness of the anode substrate and a thickness of the cathode substrate are determined based on the curvature of the respective substrate, such that the one of the anode substrate and the cathode substrate with a larger curvature has a larger thickness.

Abstract: Disclosed are a stacked-electrode battery cell that has offset electrode-to-terminal bonds, and a method for manufacturing such a cell. The stacked-electrode battery cell can comprise an external connection terminal that includes a flat tab, and a plurality of flat electrodes stacked along a first coordinate axis and collectively forming at least a portion of an anode or a cathode of the battery cell. A first electrode of the plurality of flat electrodes is bonded to a first bond region of the tab and a second electrode of the plurality of flat electrodes is bonded to a second bond region of the tab, where the first bond region and the second bond region are non-overlapping along at least one coordinate axis perpendicular to the first coordinate axis.

Abstract: Examples disclosed herein relate to a continuous separator having perforations to help reduce or prevent wrinkling of the separator when producing curved electrode stacks. One example provides a battery comprising a plurality of discontinuous electrode layers, and a continuous separator separating the discontinuous electrode layers, the continuous separator having perforations extending at least partially through a depth of the continuous separator in a folded region of the continuous separator.

Abstract: Examples are disclosed herein that relate to curved batteries. One example provides a battery comprising an anode arranged on an anode substrate, a cathode arranged on a cathode substrate, the anode substrate being curved at a first curvature and the cathode substrate being curved at a second curvature, and a separator between the anode and the cathode. A thickness of the anode substrate and a thickness of the cathode substrate are determined based on the curvature of the respective substrate, such that the one of the anode substrate and the cathode substrate with a larger curvature has a larger thickness.

Abstract: Methods and systems for detecting and compensating for expansion of rechargeable batteries over time. An expansion detector may be coupled to or positioned proximate a rechargeable battery to monitor for expansion thereof. After expansion exceeding a selected threshold is detected, the expansion detector may report the expansion to an associated processing unit. The processing unit may undertake to arrest further rechargeable battery expansion by modifying or changing one or more characteristics of charging and/or discharging circuitry coupled to the rechargeable battery. For example, the processing unit may charge the rechargeable battery at a lower rate or with reduced voltage after detecting expansion.

Abstract: A battery assembly includes a battery cell with leads extending from the battery and a circuit including a substrate and contacts that extend from the substrate. The leads are coupled to the contacts by mechanical or adhesive bonds located on sections of the contacts extending from the substrate. In various implementations, the circuit may include a variety of different components coupled to the substrate. Such components may be operable to perform a variety of functions such as regulating, monitoring, controlling, and/or otherwise managing the battery cell. Such components may include one or more battery management units, safety circuits, capacity gauges, and/or other components.