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

1 . A battery pack, comprising:

a housing;

at least two rechargeable battery cells disposed within the housing;

at least one phase change material (PCM) pouch including:

a first PCM pouch disposed between and in contact with the at least two rechargeable battery cells, one rechargeable battery cell on each side of the first PCM pouch; and

a second PCM pouch disposed on an opposite side of the first PCM pouch and in contact with a first one of the rechargeable battery cells;

electrical conductors electrically connected to the at least two rechargeable battery cells to enable electrical power to be conducted to and from the at least two rechargeable battery cells;

a first printed circuit board (PCB); and

a second PCB in electrical communication with the first PCB via a flexible circuit board including electrical conductors disposed as trace lines, the first, second, and flexible circuit boards forming a rigid-flex printed circuit board, and 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 of the rigid-flex PCB extending toward and centrally aligned between the rechargeable battery cells.

2 . The battery pack according to claim 1 , wherein the battery pack further includes a foam element positioned on an opposite side of the first PCM pouch from the rechargeable battery cell with which the first PCM pouch is in contact.

3 . The battery pack according to claim 2 , further comprising:

a frame configured to support the first PCB, and wherein the rigid-flex PCB includes a flexible cable electrically connecting the first PCB with the second PCB;

a flexible cable electrically connecting the first PCB with the second PCB;

second and third flexible cables connecting the second PCB with each of the rechargeable battery cells to supply the electrical power to and from the rechargeable battery cells; and

wherein the housing includes a first housing part and a second housing part configured to connect with and secure to the first housing part, the housing formed by the first and second housing parts being connected with one another, and configured to enclose: (i) the frame, (ii) first PCB, (iii) one rechargeable battery cell, (iv) first PCM pouch, (v) another battery cell, (vi) second PCB pouch, and (vii) foam element.

4 . The battery pack according to claim 1 , further comprising end-foam pieces configured to be positioned at each end of the at least two rechargeable battery cells within the housing.

5 . The battery pack according to claim 1 , wherein the housing is configured to be enclosed within a housing of a barcode scanner.

6 . The battery pack according to claim 1 , wherein a volume of PCM material of the at least one PCM pouch is configured to maintain a battery cell temperature below a temperature threshold during a charging thereof.

7 . The battery pack according to claim 1 , wherein the at least two rechargeable battery cells are electrically connected in a parallel configuration.

8 . 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.

9 . The method according to claim 8 , further comprising placing foam on an opposite side of the first PCM pouch from the rechargeable battery cell with which the first PCM pouch is in contact.

10 . The method according to claim 8 , further comprising placing end-foam pieces at each end of the at least two rechargeable battery cells within the housing.

11 . The method according to claim 8 , further comprising forming the first and second housing parts to be installed within a housing of a barcode scanner.

12 . 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.

13 . The mobile device according to claim 12 , wherein the battery pack further includes a foam element positioned on an opposite side of the first PCM pouch from the rechargeable battery cell with which the first PCM pouch is in contact.

14 . The mobile device according to claim 13 , further comprising:

a frame configured to secure the first PCB, and wherein the rigid-flex PCB includes a flexible cable electrically connecting the first PCB with the second PCB;

second and third flexible cables connecting the second PCB with each of the rechargeable battery cells to supply the electrical power to and from the rechargeable battery cells, and

wherein the housing includes a first housing part and a second housing part configured to connect with and secure to the first housing part, the housing formed by the first and second housing parts being connected with one another, and configured to enclose: (i) the frame, (ii) first PCB, (iii) one rechargeable battery cell, (iv) first PCM pouch, (v) another battery cell, (vi) second PCB pouch, and (vii) foam.

15 . The mobile device according to claim 12 , further comprising a temperature sensor configured to sense temperature of at least one of the rechargeable battery cells, and wherein the processor is configured to:

measure the sensed temperature of the at least two rechargeable battery cells;

determine an amount of time that the at least two rechargeable battery cells is at a melting temperature of the at least one PCM pouch; and

in response to determining that the amount of time is below a time for PCM in the PCM pouch changes from a solid to a liquid, apply a first electrical power control signal to the electrical power electronics to cause the electrical power electronics to output a first electrical power level,

otherwise, in response to determining that the amount of time crosses a threshold time for the PCM in the PCM pouch to change from a solid to a liquid, apply a second electrical power control signal to the electrical power electronics to cause the electrical power electronics to output a second electrical power level, thereby charging the at least two rechargeable battery cells.

16 . The mobile device according to claim 12 , wherein the at least one PCM pouches includes multiple PCM pouches including the same PCM material.

17 . The mobile device according to claim 12 , wherein the first PCB includes a controller configured to monitor, control, and/or interrupt operation of the battery pack.

18 . The mobile device according to claim 17 , wherein the controller is configured to receive a temperature signal from one or more temperature sensors disposed on the first PCB, a second PCB, or on a wall of one of the at least two rechargeable battery cells.

19 . The mobile device according to claim 12 , wherein the rigid-flex PCB includes the electrical conductors disposed as trace lines.

20 . The mobile device according to claim 12 , wherein the first PCM pouch contacts both of the at least two rechargeable battery cells.