Common Building Block (CBB)

Battery Pack for Notebooks

Design Guide

April 2007

Revision 1.1
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2 Design Guide
Contents
1 Introduction ...................................................................................................... 7
1.1 Scope.................................................................................................... 7
1.2 Terminology ........................................................................................... 8
1.3 Related Documents ................................................................................. 9

2 Battery Pack Features .......................................................................................10

2.1 Overview ..............................................................................................11

3 Electrical Design Considerations .........................................................................16

3.1 Overview ..............................................................................................16
3.2 Male Connector Pinout Definition for Different System Stack-Up ..................17
3.3 Electrical Design Considerations...............................................................19
3.3.1 Capacity Rating ........................................................................19
3.3.2 Discharge Current, OCP and Delay Time ......................................19
3.3.3 Charge Current, OCP and Delay Time ..........................................20
3.3.4 TOPERATING and OTP.....................................................................20
3.3.5 Data Flash Constants ................................................................21
3.4 General Electrical Design Considerations...................................................21
3.4.1 ESD Issues ..............................................................................21
3.4.2 Other Design Considerations ......................................................22
4 Mechanical Design Requirements ........................................................................23
4.1 Overview ..............................................................................................23
4.2 Pack Configurations: Six or Nine Cells ......................................................23
4.3 Chassis Interface: Rear Plug....................................................................27
4.4 Interchangeable Design Features .............................................................29
4.4.1 Alignment and Retention ...........................................................29
4.4.2 Chassis Latch Options ...............................................................30
4.4.3 Chassis Latch Operation ............................................................31
4.4.4 Latch Ergonomic Design ............................................................31
4.4.5 Motherboard Connector Options .................................................32
4.4.6 Motherboard Connector .............................................................32
4.5 Cosmetic Battery Cover ..........................................................................33
4.5.1 Cosmetic Battery Cover Catch Points...........................................36
4.5.2 Cosmetic Battery Cover Installation and Removal .........................38
4.5.2.1 6-Cell BP ..................................................................38
4.5.2.2 9-Cell (In-Line) BP .....................................................42
4.5.2.3 9-Cell (Triangular) BP.................................................44
4.5.3 Cosmetic Battery Cover Geometry ..............................................46
5 Additional Information.......................................................................................55

Design Guide 3
Figures
Figure 1. 6-Cell Stack in the 2S3P Configuration ...................................................10
Figure 2. 9-Cell Stack in the 3S3P Configuration ...................................................10
Figure 3. Battery Pack Diagram ..........................................................................12
Figure 4. Reference Design of CNT1 and CNT2 Function Using TI Solution ................14
Figure 5. Reference Design of CNT1 and CNT2 Function Using Renesas Solution .......15
Figure 6. Single-Pack Support Conventional Platform ............................................16
Figure 7. Dual-Pack Support Conventional Platform...............................................17
Figure 8. Different System Stack-Up ...................................................................18
Figure 9. Pinout for the Male Connector on the Motherboard ..................................18
Figure 10. Male Battery Connector ......................................................................22
Figure 11. Dropped Hinge Platform Design with the two 9-Cell BP versions ..............24
Figure 12. Center line distance requirement between 9-Cell (Triangular) BP and
Notebook widths ........................................................................................24
Figure 13. Extended feature of 9-cell (Triangular) cosmetic cover when BP is located
further away from notebook center...............................................................25
Figure 14. Top and End Views of Battery Cavity in Chassis for either 6 or 9-cell BP ...26
Figure 15. Chassis Cavity (Side View)..................................................................26
Figure 16. Optional Cosmetic Battery Cover 6-cell (Small External Radius) ..............27
Figure 17. Maximum Chassis Cavity with 9-cell (In-Line) BP...................................27
Figure 18. Section View of a 6-Cell or 9-Cell (Triangular) Battery Pack Plugged into
Rear of Chassis ..........................................................................................28
Figure 19. Section View of 9-Cell (in-line) Pack Plugged into Rear of Chassis............28
Figure 20. The Position of the Battery Connector in the Z Direction .........................29
Figure 21. Battery Pack Guides...........................................................................30
Figure 22. Battery Pack Latch Points ...................................................................30
Figure 23. Toggle and Spring Loaded Latches.......................................................31
Figure 24. Ergonomic Latch Design Example ........................................................32
Figure 25. Male Battery Pack Connector Shown on Primary and Secondary Sides ......32
Figure 26. Texture Surfaces (6-Cell BP) ...............................................................33
Figure 27. Texture Surfaces (9-Cell, In-line, BP) ...................................................33
Figure 28. Texture Surfaces (9-Cell, Triangular, BP) ..............................................34
Figure 29. Wrap Around Cover (6-cell) ................................................................35
Figure 30. Extended Wrap around Cover (9-Cell in-line) ........................................35
Figure 31. Extended Wrap around Cover (9-Cell Triangular) ...................................35
Figure 32. Cosmetic Cover Interface Features for 6-Cell BP ....................................36
Figure 33. Cosmetic Cover Interface Features for 9-Cell (In-Line) BP.......................37
Figure 34. Cosmetic Cover Interface Features for 9-Cell (Triangular) BP ..................37
Figure 35. Battery Pack without Cosmetic Battery Cover (Rear Catch Points Covered
by Label) ...................................................................................................38
Figure 36. Installation Process for 6-Cell Cosmetic Battery Cover............................39
Figure 37. Removal Indents for 6-Cell CBB Battery Pack ........................................39
Figure 38. Removal Process for 6-Cell Cosmetic Battery Cover ...............................40
Figure 39. Extraction Tool Reference Drawing ......................................................40
Figure 40. Extraction Tool Reference Positioning ...................................................41
Figure 41. Extraction Tool Motion........................................................................42
Figure 42. Installation Process of 9-Cell (In-Line) Cosmetic Battery Cover ...............43
Figure 43. Sequence of Actions for 9-Cell (In-Line) Cosmetic Battery Cover Installation43
Figure 44. Sequence of Actions for 9-Cell (In-Line) Cosmetic Battery Cover Removal 44
Figure 45. Installation Process of 9-Cell (Triangular) Cosmetic Battery Cover ...........44
Figure 46. Sequence of Actions for 9-Cell (Triangular) Cosmetic Battery Cover
installation.................................................................................................45

4 Design Guide
 Figure 47. Sequence of Actions for 9-Cell (Triangular) Cosmetic Battery Cover
Removal....................................................................................................45
Figure 48. Example of a 6-Cell Cosmetic Battery Cover .........................................46
Figure 49. Example of a 9-Cell (In-Line) Cosmetic Battery Cover ............................46
Figure 50. Example of a 9-Cell (Triangular) Cosmetic Battery Cover........................47
Figure 51. Cosmetic Battery Cover Geometry for 6-Cell (Page 1 of 2)......................48
Figure 52. Cosmetic Battery Cover Geometry for 6-Cell (Page 2 of 2)......................49
Figure 53. Cosmetic Battery Cover Geometry for 9-Cell, In-Line (Page 1 of 2) ..........50
Figure 54. Cosmetic Battery Cover Geometry for 9-Cell, In-Line (Page 2 of 2) ..........51
Figure 55. Cosmetic Battery Cover Geometry for 9-Cell, Triangular (Page 1 of 3)......52
Figure 56. Cosmetic Battery Cover Geometry for 9-Cell, Triangular (Page 2 of 3)......53
Figure 57. Cosmetic Battery Cover Geometry for 9-Cell, Triangular (Page 3 of 3)......54
Figure 58. Ergonomic ID Feature (with Cosmetic Battery Cover Case) .....................54

Tables
Table 1. Nomenclature ....................................................................................... 8
Table 2. Related Documents................................................................................ 9
Table 3. Functional Description of CNT1 and CNT2 Pin ...........................................13

Design Guide 5
Revision History

Revision Description Revision Date

Number

1.0 Initial release. November 2006

1.1 • Verbiage changes / formatting April 2007

• Changed word LIBP to CBB BP on several Figures
• Added note that Permanent Adhesive should not be used
between Cosmetic Battery Cover and Battery Pack

6 Design Guide
Introduction

1 Introduction
In today’s notebook industry, every notebook PC platform has its own battery pack
design to meet the specific platform design requirements. This approach incurs
redundant time, effort, and expense to the platform design and integration. The
consequence is the lack of efficiency, wasted R&D resources, prolonged design cycle,
and delayed product introduction. These issues can be overcome by Common Building
Block (CBB) Battery Pack (referred to as battery pack or BP within this document).
Conceptually the redundant resources could be reduced by wide adoption of few
compliant pack SKU’s. Thus the system designers or integrators can put more effort
on high value added features and more innovative designs.

CBB Battery Pack takes an evolutionary approach in utilizing not only the industrial
specifications as listed in Section 1.3, but also the common ingredients available in
the battery technology today as described in Chapters 2 and 3. Additionally, the
battery pack could adapt gracefully to the trend for longer battery life by deploying
future cells with new chemistry, higher capacity, slimmer sizes, and so forth. Hence
the battery pack is scalable to the need of future notebook PC platforms.

As described in Chapter 4, the notebook platforms with battery packs require a unique
cavity design on the rear side to incorporate with the battery pack. Also, the optional
cosmetic battery cover for the battery pack helps to satisfy the market need for pack
differentiation such that it fits to various notebook ID requirements with a different
look and feel, color and texture, without any redesign of the battery pack itself.

From the supply chain point of view, the benefit to the industrial participants by
adopting the CBB Battery Pack is obvious. For a limited SKU’s of battery packs
required, CBB Battery Pack can help reduce the inventory cost of excess or obsolete
packs, and prevent the sales loss due to the stock shortage. As the demand from
ODM’s and OEM’s could be aggregated, the pack suppliers get the chance to reach the
emerging markets, and can possibly average the tooling cost, automate the
production process, which in turn could lower the product cost for high volume
manufacturing of the battery pack..

1.1 Scope
This design guide provides the platform design and integration guidelines for Intel
Architecture based notebook platforms using CBB battery Pack. These design
guidelines have been developed to ensure maximum flexibility for notebook system
designers and integrators while reducing the risk of battery pack design related
issues. The intended audiences are notebook system designers and integrators, as
well as battery pack suppliers who need to comprehend the CBB Battery Pack
requirements.

Design Guide 7
 Introduction

1.2 Terminology
Table 1. Nomenclature

Term Description

AFE Analog Front End

BMU Battery Management Unit

BP Battery Pack

CBB Common Building Block

EBL Extended Battery Life

ESD Electro-static discharge

IMPAM Intel Mobile Power Adapter Monitor

NVDC Narrow Voltage DC

ODM Original Design Manufacturer

OEM Original Equipment Manufacturer

SMC System Management Controller

8 Design Guide
Introduction

1.3 Related Documents

Table 2. Related Documents

Document Document Number/Location

Common Building Block Battery Pack (CBB) www.mobileformfactors.org

Specification

Narrow VDC Extended Battery Life (EBL) 300344

Specification http://developer.intel.com/design/mobil
e/platform/idf/300344.htm

Smart Battery Charger Specification (Rev 1.1) Smart Battery Systems Implementers
Forum*, http://www.sbs-
Smart Battery Data Specification (Rev 1.1) forum.org/specs/index.html
Smart Battery Selector Specification (Rev 1.1)
Smart Battery System Manager Specification
(Rev 1.1)

System Management Bus (SMBus) Specification System Management Interface Forum*,

(Rev 2) http://www.smbus.org/specs/
SMBus Control Method Interface Specification,
(Rev 1)
SMBus Device Driver External Architecture
Specification (Rev 1)

Safety Documents:
UL 2054 (Household and Commercial Batteries) UL
UL 1642 (Standard for Lithium Batteries)
IEEE 1625 IEEE
IATA International Aircraft Transportation
USDOT 49 CFR 173.185F Association
http://hazmat.dot.gov/regs/notices/npr
m/2002_11989.htm

EU Restriction on Hazardous Substances (RoHS) http://europa.eu.int/eur-

Directive lex/pri/en/oj/dat/2003/l_037/l_0372003
0213en00190023.pdf

Design Guide 9
 Battery Pack Features

2 Battery Pack Features

CBB Battery Pack uses a 6 or 9 18650 cell configuration. The 6-cell design contains a
3-series, 2-parallel (3S2P) configuration and the 9-cell design contains a 3-series,
3-parallel (3S3P) configuration, as illustrated in Figure 1 and Figure 2 respectively.
The battery pack is capable of supporting future battery technologies like Prismatic
cells

Figure 1. 6-Cell Stack in the 2S3P Configuration

18650 18650 18650

18650 18650 18650

VH V2 V1 VL

Figure 2. 9-Cell Stack in the 3S3P Configuration

18650 18650 18650

18650 18650 18650

18650 18650 18650

VH V2 V1 VL

The battery pack is designed to be mounted at the rear of the platform. An optional
snap-on battery pack cosmetic battery cover can be designed to provide a
differentiated look and feel particular to any given system’s industrial design.

The electrical interface is compliant with SMB v1.1. The 9-pin connector can support
up to 10 A.

10 Design Guide
Battery Pack Features

2.1 Overview
Referring to Figure 3, the CBB Battery Pack contains the following:
• Battery Stack configured as a 3-series, 2-parallel or 3-series, 3-parallel
• Power MOSFET’s (QCH and QDIS) used to control the charge into and out of the
battery pack
• Current Sensing Resistor (RSENSE) connected in between the Battery Stack and
GND. Current into and out of the BP flows through this current sense resistor
• Battery Management Unit (BMU) is implemented by Micro-controller, and consists
of Gas Gauging, Switch Control, Protection, Current Measurement, Interface
control functions. The Battery Current Measurement block monitors the current
across RSENSE, and the Protection block monitors the voltage across the Battery
Stack.
• Analog Front End (AFE) consists of Miscellaneous control and Switch control. AFE
is implemented by the analog front end ICs in which the Switch Control block
turns on or off the Power MOSFET’s to ensure safe operations.
• The battery pack interfaces to the notebook platform via the 9-pin connector as
described in Section 3.2. Please refer to Common Building Block Battery Pack
Specification as listed in Section 1.3 for the complete pin definitions.

Design Guide 11
 Battery Pack Features

Figure 3. Battery Pack Diagram

Power Switches
Q CH Q DIS
BATT +

Fuse

CNT1
Switch
CNT2 Misc. Battery
Control
control Stack
CLK
DATA
Interface Protection
THRM
NTC
Therm .
Gas Battery Current
RSENSE
Gauging Measurement
GND

NOTE: The BATT+, GND, CLK, DATA and THRM pins behave similar to those of Conventional
Battery Pack.

12 Design Guide
Battery Pack Features

Refer to Table 3 for the functional description of the CNT1 and CNT2 pins. Notice that
the BMU’s Protection Circuitry (Over-current, Over-voltage, etc.) has priority over the
CNT1 and CNT2 signals. That is, if there is an unsafe condition (over-current, over-
voltage, etc.), the BMU will turn off the Power MOSFET’s regardless of the status of
the CNT1 and CNT2 signals. For more information about the safety features and
protection mechanism of Battery Pack, please refer to Common Building Block Battery
Pack Specification as listed in Section 1.3.

During normal operation (safe condition), the Power MOSFET’s are controlled by the
CNT1 and CNT2 signals as defined in Table 3. Note that for the battery pack
designers, the CNT1 and CNT2 pins of the BP design must be pulled up with 1-MΩ
resistors independently. Before BP insertion or after pulling out from the platform, it
will switch to the OFF the state according to Table 3 to ensure safety operation. For
the system designers, if Intel Mobile Power Adapter Monitor (IMPAM) (formerly called
NVDC) is not implemented, the platform needs to tie both CNT1 and CNT2 pins to
ground. After insertion to a platform, BP is turned on according to Table 3 and
behaves like a conventional battery pack. The Low-Current Discharge and Low-Current
Charge conditions will be covered in Section 3.1.

Table 3. Functional Description of CNT1 and CNT2 Pin

CNT11, 2
CNT21, 2
CHARGE3 DISCHARGE QCH3 QDIS3 Status
3

0 0 0 0 ON ON Battery Pack ON

0 1 0 0 ON OFF Low Current Charge

Low Current
1 0 0 0 OFF ON
Discharge

1 1 0 0 OFF OFF Battery Pack OFF

0 0 0 1 ON OFF Low Current Charge

0 1 0 1 ON OFF Low Current Charge

1 0 0 1 OFF OFF Battery Pack OFF

1 1 0 1 OFF OFF Battery Pack OFF

Low Current
0 0 1 0 OFF ON
Discharge

0 1 1 0 OFF OFF Battery Pack OFF

Low Current
1 0 1 0 OFF ON
Discharge

1 1 1 0 OFF OFF Battery Pack OFF

0 0 1 1 OFF OFF Battery Pack OFF

0 1 1 1 OFF OFF Battery Pack OFF

1 0 1 1 OFF OFF Battery Pack OFF

1 1 1 1 OFF OFF Battery Pack OFF

NOTES:
1. Battery pack vendors: 1-MΩ pull up resistor required on CNT1 and CNT2 pins.

Design Guide 13
 Battery Pack Features

2. System Designers: If NVDC (or the new code name IMPAM) not implemented, the
system needs to tie CNT1 and CNT2 pins to ground.
3. See Figure 2

Following are two reference designs of the CNT1 and CNT2 truth table for the BP
designers. For the BP circuit using TI* BQ2084 gas gauge controller and BQ29312
AFE, it is recommended to reference the LS Circuit in Figure 3. The second one is for
those designs with Renesas* gas gauge controller M37512 and R2S20020 AFE. The
CNT1 and CNT2 external control circuit is embedded in the R2S20020 that requires no
extra switching components. See Figure 4.

Figure 4. Reference Design of CNT1 and CNT2 Function Using TI Solution

QCH QDIS
1
BATT+
2

VCC VCC
Q2 Q4
R2 R4

3
CNT1 R1 R3 LS
Q1 Q3
4
CNT2 Circuit
R CH R DSG

CH DSG

AFE

5
CLK

6
DATA Controller
7
THRM

8
BATT- Thermistor

14 Design Guide
Battery Pack Features

Figure 5. Reference Design of CNT1 and CNT2 Function Using Renesas Solution

Q CH Q DIS
BATT+
1
2

CNT1
3
CNT2
4
AFE
(R2S20020)

CL
Controller
5
DATA
6
THRM
(M37512)
7
Thermistor
BATT-
8

Design Guide 15
 Electrical Design Considerations

3 Electrical Design
Considerations

3.1 Overview
This section describes the design of a Single-Pack and Dual-Pack CBB Battery Pack.
Figure 6 depicts the Single-Pack Design. The CNT1 and CNT2 pins are tied low and as
a result the battery pack behaves like a conventional battery pack. The System
Management Controller (SMC) is used to interface to BP. It also controls the Adapter
Switch (QAD1 and QAD2) and the Battery Switch (QBATT) in addition to the Battery
Charger.

Assuming that the AC/DC Adapter (19-V output voltage) is plugged into the platform
and the Adapter Switches (QAD1 and QAD2) are on, it provides power to the Battery
Charger and the rest of the system through the VDC node. During this time, the
battery switch, QBATT is off isolating the battery pack from the VDC node. If the AC/DC
Adapter is not plugged into the platform, battery pack provides power to the VDC
node via QBATT. The mechanical design guidelines for the Single-Pack battery pack will
be covered in Chapter 4.

Figure 6. Single-Pack Support Conventional Platform

Adapter Switch
Battery Charger VDC DC-DC
AC/DC
Adapter QAD1 QAD2
Converters
QCHRHS
Battery LCHR R CHR QBATT System
Charger
Loads
Controller Q CHRLS

Power Switch
Control Logic
BATT +

CNT1

CNT2 AFE
Linear
VR
SMC CLK

DATA
BMU
THRM

GND

CBB BP

In the case that the battery pack is fully discharged or deeply discharged, for example
the internal circuitry of the pack does not have enough voltage to turn on, it is unsafe
to provide a typical charge rate to the pack. As such, it is necessary to provide a slow
wake up charge current. This slow charge current can be handled by placing the
battery pack into the low-current charge condition. The Battery Charger can modify its
output current to the battery pack to ensure safe slow charging. Once the pack has

16 Design Guide
Electrical Design Considerations

enough voltage, the internal circuitry can start to communicate with the SMC and if
necessary, the charge rate can be increased to a typical rate as defined in the
Common Building Block (CBB) Battery Pack for Notebooks Specification.

In the case of starting up the system where there is no AC/DC Adapter presence, the
battery pack can be placed in a slow-discharge rate to wake up the SMC. This slow
discharge current can be handled by placing the battery pack into the low-current
discharge condition.

Figure 7 depicts the operation of a Dual-Pack Support Conventional Platform with two
battery packs. To prevent erroneous charge/discharge conditions between the two
battery packs, the Power Switch and the Selector is inserted with series-configured
MOSFET’s. Similar to what was previously described, the SMC can control the PS
MOSFET’s in addition to the APS adapter switches and the Battery Charger.

Figure 7. Dual-Pack Support Conventional Platform

APS Battery Charger

AC/DC RADP
VDC
Adapter DC-DC
QAD1 Q AD2
Q CHRHS
Converters
Battery R CHR

Charger LCHR
System
Controller Q CHRLS QC1
Q D1 Q D2
Q C2
Loads
QB1 Q B2
C1
B1
D1
PS
Selector D2
B2
C2

BATT+ BATT+

CNT1 CNT1
CNT2 AFE CNT2 AFE
SMC
Conventional
CLK CLK

DATA BMU DATA BMU

THRM THRM

Design
GND GND

CBB BP CBB BP

3.2 Male Connector Pinout Definition for Different

System Stack-Up
The connector on the CBB Battery Pack is symmetrical allowing for the use of the
same male connector on the baseboard enabling different system Stack-Up, such as:
• Motherboard above the battery pack connector
• Motherboard below the battery pack connector
• Motherboard is placed in-line with the battery pack connector

Please refer to Figure 8 for further details.

Design Guide 17
 Electrical Design Considerations

Figure 8. Different System Stack-Up

MB Primary Side Up

Same Male Connector for 2

different system placements

MB Primary Side Down

The circuit designer should ignore the pin 1 designation of the male connector, which
may differ from vendor to vendor. Instead, the pin assignments should be matched to
the pinout of the battery pack power connector, as shown in Figure 9.

Figure 9. Pinout for the Male Connector on the Motherboard

BATTERY PACK

Pin 1

BASE BOARD Pack+

CNT1
CNT2
CLK
DATA
THRM
Pack-

TOP VIEW Drawing not to scale

18 Design Guide
Electrical Design Considerations

3.3 Electrical Design Considerations

This section highlights important electrical design considerations of CBB Battery Pack.
For battery pack designers, as long as the battery pack design meets the CBB
electrical and mechanical requirement, there is no limitation as to which vendors’ gas
gauge controller, AFE, other key components, or firmware version are used. The
system designers must verify whether their systems using CBB BP would work
compatibly with all battery pack SKU’s from each supplier. For complete electrical
requirement refer to Chapter 2 of Common Building Block (CBB) Battery Pack for
Notebooks Specification.

3.3.1 Capacity Rating

The typical capacity rating is 53 Whr for the 6-cell (53 Whr / 11.1 V = 4.8 Ah) and
79.9 Whr for the 9-cell (79.9 Whr/11.1=7.2Ah) CBB Battery Pack. Note that these are
typical, not maximum, ratings. The battery pack design is not limited to adopting a
2400 mAh or higher capacity Lithium ion cells as long as the characteristics of the
battery pack are spec-compliant. See Section 2.1.2.1 for the capacity rating
requirement of the Common Building Block (CBB) Battery Pack for Notebooks
Specification.

3.3.2 Discharge Current, OCP and Delay Time

The CBB Battery Pack must be designed to support up to 10A discharge current
capability in order for the battery pack to meet expected platform requirements. It is
required to discharge at 10A up to 30 sec before the Over Current Protection
mechanism is automatically triggered to turn off the discharge MOSFET. See Section
2.1.2.4 for the discharge current, and Section 2.1.3.3 for the Discharge OCP Current
and Delay Time requirement detailed in the Common Building Block (CBB) Battery
Pack for Notebooks Specification.

The system designer or integrator may verify the discharge current and OCP
capabilities of a battery pack by an electric load. The battery pack must be able to
sustain 10 A for 30 seconds before the OCP Discharge is triggered. During the test,
the SMBus activity is required to keep the battery pack from entering the sleep mode.
If there is no SMBus activity during the test, the charging MOSFET in the OFF state
and the fuse could be damaged because of the rapid heat accumulated due to the
huge current drained by the electric load that exceeds the fuse temperature threshold.

The battery pack suppliers should conduct chamber testing to validate the robustness
and spec-compliance of their battery pack design for its discharge current and OCP
capability. The ambient temperature of the test setting is set to 45 °C, TOPERATING of
the battery pack. During the discharge current chamber test, the battery pack under
test and all sub-components should not exceed their individual electrical ratings or
requirements on voltage, current or temperature.

Design Guide 19
 Electrical Design Considerations

3.3.3 Charge Current, OCP and Delay Time

The CBB Battery Pack is designed to support 4.8A or 1-C maximum charging current
capability. The Over Current Protection (OCP) mechanism should be automatically
triggered to turn off the charging MOSFET if the charging current is over 5 A for 2
seconds. The tolerance of the Delay Time 2 seconds is ±50%. It is recommended to
set a minimum gap of 200 mA between the max Charge Current and the OCP Charge
Current in order to prevent transient inrush charge current that causes a false action
to turn off the charging MOSFET. In addition, when the battery pack reaches the full
charge condition, the charging MOSFET must be turned off to prevent over charge.
Note that the charge or pre-charge current is system-generated so the pack would be
expected to handle it, rather than generate it. See Section 2.1.2.3 for the charge and
pre-charge current, and Section 2.1.3.3 for the Charge OCP Current and Delay Time
requirements detailed in the Common Building Block (CBB) Battery Pack for
Notebooks Specification.

The system designer or integrator may verify the max charge current and OCP
capability of a battery pack with a power supply. During the test, the SMBus activity is
required to ensure the battery pack under test is constantly kept in the run mode.

The battery pack suppliers should conduct chamber testing to validate the robustness
and spec-compliance of their battery pack design for its charge current and OCP
capabilities. The ambient temperature of the test setting is set to 45 °C, the maximum
of TOPERATING. During the charge current chamber test, the battery pack under test and
all sub-components should not exceed their individual electrical ratings or
requirements on voltage, current or temperature.

3.3.4 TOPERATING and OTP

The ambient temperature or TOPERATING is the temperature within which a CBB Battery
Pack would have to operate. The correct measurement points are on the cells, not on
the pack. Over Temperature Protection (OTP) is the thermal throttling and protection
mechanism of a battery pack to prevent over-heating that could damage the battery
components or cause safety problems. See Section 2.1.2.6 of Common Building Block
(CBB) Battery Pack for Notebooks Specification for the temperature related
specifications.

The battery pack charge/discharge initial temperature is 0~45 °C. That is, the battery
pack begins to charge or discharge only if the outer surface temperature of the cells is
between 0 and 45 °C. It would stop charging or discharging if the outer surface
temperature of the cells is above 60 °C. When the temperature drops below 45 °C,
the corresponding charge or discharge MOSFET can be turned on again.

In case thermal throttling of the battery pack happens so frequently to interrupt

normal battery operation, the battery pack designers should consider various
alternatives to reduce the overall heat of the battery pack, such as replacing those key
components (MOSFET, thermal sense resistor) with larger power rating, widening the
power conducting path or flood, or other techniques that helps heat dissipation.

20 Design Guide
Electrical Design Considerations

3.3.5 Data Flash Constants

The behavior and performance of a CBB Battery Pack is decided by the parameter
settings or constants stored in the EEPROM or Data Flash. For the battery pack
suppliers, it is required to put the Device Name frame started with “LIBP6” or “LIBP9”.
For the system designers, the platform must be able to turn on the battery pack when
these strings are read and detected to ensure interchangeability.

Both the charge and pre-charge current are provided by the system charger instead of
by battery pack itself. The system reads the current rating related constants stored in
the Data Flash via the SMBus. For the system designer, the platform using the battery
pack should be designed flexible enough to provide the charge and discharge current
as specified by the Data Flash constants.

Both the battery pack and system designers must include checks of the data flash
constants as part of the validation plan. The test procedure includes reading the data
flash constants of the battery pack via the SMBus, and then comparing and checking
those key parameters with respect to the Common Building Block (CBB) Battery Pack
for Notebooks Specification. This will help to ensure that the battery pack Data Flash
and the system BIOS are compatible and eliminate potential integration or
interchangeability issues after product launch. For those Data Flash constants that are
not defined in the Common Building Block (CBB) Battery Pack for Notebooks
Specification, the battery pack or system designers may use these for product feature
differentiation to meet various engineering or business considerations.

3.4 General Electrical Design Considerations

This section discusses other electrical design consideration when designing systems
using the CBB Battery Pack.

3.4.1 ESD Issues

It is recommended to use at least two long “first mate” pins at both ends of the male
battery connector for the baseboard. Please refer to Figure 10. This allows the ESD to
be discharged through the power rail when the battery pack is plugged onto the
system. It is expected that the system designer will design in ESD circuitry to handle
possible ESD discharges for all the signal pins.

Design Guide 21
 Electrical Design Considerations

Figure 10. Male Battery Connector

Long Pins
Connector Housing

TOP VIEW
Drawing not to scale

The general ESD design practice should include, but not be limited to the following:
1. Connect a high frequency bypass capacitor between the Vcc and Ground pin, with
minimal PCB trace lengths to minimize inductance. This bypass capacitor should
have low internal series inductance. Hence electrolytic capacitors should be
avoided. In general, a ceramic chip capacitor in the range of 0.1 µF to 0.2 µF
should be adequate. This bypass capacitor also helps in alleviating the effect of
parasitic inductance in the Vcc return path.
2. Use ESD protection devices, such as protection diode array, on all the connector
signal pins. The ESD protection device should be ideally connected directly to the
Vcc and Ground planes (or through multiple vias).
3. The ESD protection device should be placed close to the point of entry of an
expected ESD. This ensures the ESD energy is absorbed and dissipated safely as
quickly as possible on entry and minimize disturbance to the rest of the system.
4. Use Vcc and ground planes for power and ground distribution if possible. This is a
general design practice for signal shielding yet also helpful to reduce the impact of
high voltage transient.

3.4.2 Other Design Considerations

Since the connector is symmetric, the CBB Battery Pack may inadvertently be inserted
onto a bare motherboard backward, i.e. the “+” terminal to the “ – ”. This may only
happen in a test environment when the motherboard is not mounted on a chassis.
When the pack is used in such environment, it is prudent to have clear label correctly
identifying the pin 1 location of the battery pack. The pack itself will also have a “pin
1” and “pin 9” or “+” and “-” indicator on its housing.

22 Design Guide
Mechanical Design Requirements

4 Mechanical Design
Requirements
This chapter outlines the basic assumptions for integrating the CBB battery Pack into
notebook platforms and may possibly extend to other types of mobile platforms.

4.1 Overview
The following section is an overview of the design philosophy for the pack and how it
integrates into the notebook. More specific details will be presented later in this
chapter.

4.2 Pack Configurations: Six or Nine Cells

As mentioned in Chapter 2, there are 6-cell and 9-cell CBB Battery Pack designs.
There are two versions of the 9 cell CBB battery pack. One version is the in-line
configuration. A second version is the triangular shaped configuration. In the in-line
version, all 3 rows of cells are on same plane. In the case where the platform
incorporates a dropped hinge lid only the second version (triangular shaped 9-cell BP)
is the only one of the two that eliminates clearance issues. This option has the third
row of cells below the first two (on a different plane). This adds height to the 9-cell
battery pack. Both options should be carefully considered when deciding which option
works best for a particular notebook design. Both cases mentioned above with the
Dropped Hinge notebook design and the two versions of 9-Cell BP are illustrated
below in Figure 11.

When the triangular shaped 9-cell BP is considered for a platform the designer needs
to locate it such as the center lines between the notebook and the battery pack widths
are less than 20 mm as shown in Figure 12. When a triangular shaped BP is
integrated into a notebook then the back edge of the system is being lifted off the
table surface. As the form factors are getting wider 14.1W to 17W (plus) the system
can become unstable (can rock) on a table surface when a vertical force is applied on
the edge of the keyboard and the location of the battery pack is not towards the
center of the notebook. In this situation the optional cosmetic cover can be designed
in such a way that the one side of the cosmetic cover is extended. This shifts the
center line of the BP & cosmetic cover subassembly in a way that it is closer to the
center line of the notebook width. This example is shown in Figure 13 below.

Design Guide 23
 Mechanical Design Requirements

Figure 11. Dropped Hinge Platform Design with the two 9-Cell BP versions

9-Cell In-Line BP Dropped Hinge

Dropped Hinge is not compatible with 9-Cell In-Line BP

9-Cell Triangular BP

Dropped Hinge is compatible with 9-Cell Triangular BP

Figure 12. Center line distance requirement between 9-Cell (Triangular) BP and
Notebook widths

≤ 20mm

24 Design Guide
Mechanical Design Requirements

Figure 13. Extended feature of 9-cell (Triangular) cosmetic cover when BP is located
further away from notebook center

≤ 20mm

The 6-cell battery pack is designed to insert fully into the system. Both versions of the
9-cell battery packs are designed so that only the first two rows of cells are inserted
into the system. The critical-to-function dimensions for the chassis battery cavity are
shown in Figure 14. In this figure, the upper drawing is the top view of the chassis
cavity. The bottom drawing is the end view as seen from the rear of the chassis.
Nominal dimensions are shown; however typical tolerances are ±0.15 mm. The
dimension of 49.64 mm results in a 6-cell battery pack or 9-cell triangular battery
pack without a cosmetic battery cover, fully inserting into a chassis, with the rear of
the battery pack flush with the rear of the chassis. If a cosmetic battery cover is used
with the battery pack, the datum for the battery pack connector must be moved
slightly deeper into the chassis to account for the thickness of the cover, if the ID
requirement is to have the Battery Pack flush with back of chassis. The cover
thickness will typically range from 1.2 to 1.7 mm. Figure 15 shows the two cases of
implementation (Case A: No cosmetic battery cover and Case B: with cosmetic battery
cover). In Figure 14, the 51.54 mm dimension allows the assembled dimension
between the outer surface of cosmetic battery cover and battery pack to be a
maximum of 1.90 mm. Figure 16 shows that a small external radius can be achieved
if the cosmetic battery cover is 1.90 mm.

Note that the cavity depth cannot exceed 51.54 mm because the 9-cell In-Line version
BP has a step feature on its top surface that is intended to reside outside the chassis.
If the internal system cavity is deeper than 51.54 mm, there could be interference
with the external step on the 9-cell In-Line version BP, which would prevent the full
insertion of the BP into the chassis. This is demonstrated in Figure 17.

Each integrator should have different design criteria and design rules for incorporating
the battery pack into their chassis, details of which are beyond the scope of this
design guide. The dimensions shown are for reference only.

Design Guide 25
 Mechanical Design Requirements

Figure 14. Top and End Views of Battery Cavity in Chassis for either 6 or 9-cell BP

49.64 1
40.55 1
51.54 2
42.45 2

Notes:
1. Design application w/o ID battery cover

2. Design application w/ ID battery cover (assumed 1.90mm thick cover)

Figure 15. Chassis Cavity (Side View)

LCD
49.50 mm

flush with the chassis

Case A: No ID Cover

LCD
49.50mm + Distance
(CBB BP back surface – ID Cover back surface)

flush with the chassis

Case B: w/ ID Cover

26 Design Guide
Mechanical Design Requirements

Figure 16. Optional Cosmetic Battery Cover 6-cell (Small External Radius)

Figure 17. Maximum Chassis Cavity with 9-cell (In-Line) BP

49.50 + 1.90 mm

0.40 (mm)

4.3 Chassis Interface: Rear Plug

The CBB Battery Pack plugs into the rear of the chassis. Currently, today’s battery
packs are designed in multiple cell configurations resulting in various pack form
factors. They are also integrated into the chassis at multiple locations, with different
connectors, latching features, and each being unique for a particular chassis. Plugging
the battery into the rear of the chassis alleviates many of these integration issues. As
mentioned earlier in Section 4.2, the 6- and 9-cell battery packs each mount into the
chassis from the rear of the chassis. Figure 18 presents the case for 6-Cell or 9-Cell
(Triangular) battery pack. In the case of the 9-cell (In-Line) the battery extends
beyond the 6-cell pack, as shown in Figure 19.

Design Guide 27
 Mechanical Design Requirements

Figure 18. Section View of a 6-Cell or 9-Cell (Triangular) Battery Pack Plugged into
Rear of Chassis

Figure 19. Section View of 9-Cell (in-line) Pack Plugged into Rear of Chassis

28 Design Guide
Mechanical Design Requirements

4.4 Interchangeable Design Features

The CBB Battery Pack is designed with interchangeability in mind. There are multiple
latch points available for retaining the pack into the chassis. Also, the connector is
positioned approximately in the center of the pack in the Z direction as shown in
Figure 20, to allow primary, secondary, or straddle mount motherboard connector
placement and associated interconnect. This is true for the 6-Cell and 9-Cell In-Line
BPs, however it is at the middle of the top row of cells for the 9-Cell Triangular version
BP. Although the current designs of the 6-cell battery pack is for cylindrical 18650
type cell geometry, the form factor of the battery pack is such that it will allow for
interior volume inclusion of future cell geometries such as prismatic cells.

Figure 20. The Position of the Battery Connector in the Z Direction

Z Direction

Battery Connector

4.4.1 Alignment and Retention

The CBB Battery Pack must be guided into the system such that the corresponding
pack and system connectors can properly mate. General alignment of the battery pack
with the notebook in the horizontal X-Y plane is accomplished through the use of two
female guides at the ends of the pack, as shown in Figure 21. The tolerance stack-up
of these guides along with the required male alignment guides in the chassis must
ultimately allow for proper engagement of the battery pack connector into the male
motherboard connector. The length of the guides limits rotation about the X and Z
axes during insertion, but must not inhibit or restrict insertion of the battery pack into
the system. The guides should be tapered and may include draft angles for ease of
manufacture. The guides as mounted in the chassis should be designed such that they
do not allow separation in the X-axis direction under dynamic shock and vibration
conditions that may exist during transportation. The overall tolerance stack-up and
retention within the chassis should not allow battery movement once it is latched into
the chassis. Battery movement will be perceived as a low-quality attribute, and may
lead over time to fretting corrosion at the connector interface, which could in turn,
lead to higher resistance less efficient contact points.

Design Guide 29
 Mechanical Design Requirements

Figure 21. Battery Pack Guides

Battery Pack Guide

4.4.2 Chassis Latch Options

The CBB Battery Pack is designed with four pairs of latch points. These are shown in
Figure 22 (note these are mirrored on the opposite end of the battery pack). It is
suggested that opposite pairs be used to latch the battery pack into the chassis, but
different combinations can be used.

Figure 22. Battery Pack Latch Points

4
1
2
3

30 Design Guide
Mechanical Design Requirements

4.4.3 Chassis Latch Operation

The CBB Battery Pack must be firmly secured into the system to prevent it from being
dislodged during transport, and to prevent micro-motion of the battery pack which
could lead to fretting corrosion of the connector interface and degraded performance.
A good design will allow two-hand extraction of the battery pack. The recommended
approach is to utilize two chassis slide latches to retain the battery pack, using one of
the pairs of battery pack latch points shown in Figure 22. One of these slide latches
should include detents to hold the latch in the open position for extraction. The other
latch should be spring-actuated such that it is normally forced into the closed position.
The process for extracting the battery pack is to slide the toggle latch to the open
position. Hold the spring loaded latch in the open position, and with the free hand
extract the battery pack from the system (see Figure 23).

Figure 23. Toggle and Spring Loaded Latches

4.4.4 Latch Ergonomic Design

The slide latches should be designed to minimize end-user discomfort but still provide
the proper latch functionality. The surface areas of the slide latches should be large
enough to mitigate fingertip force requirements, and should be knurled or serrated for
good traction (see Figure 24). The first slide latch should have detents to lock into the
open position. The total force to open the second latch should not exceed 10 oz
(283 g).

Design Guide 31
 Mechanical Design Requirements

Figure 24. Ergonomic Latch Design Example

4.4.5 Motherboard Connector Options

The position of the CBB Battery Pack connector is such that the battery pack can be
designed into notebooks with the male connector on either the top or bottom of the
motherboard, (see Figure 25 and also Figure 8 in Section 3.2). It is also possible to
utilize straddle mount connectors, not shown.

Figure 25. Male Battery Pack Connector Shown on Primary and Secondary Sides

4.4.6 Motherboard Connector

The male motherboard connector must work with the female connector specified in
the Common Building Block (CBB) Battery Pack for Notebooks Specification (example
part numbers for the battery pack connectors are: Suyin 200274FS009GX01ZU or
Alltop C14430-109XX, or equivalent. Because there are multiple height options for the
male motherboard connector, it will not be specifically referenced in this design guide.
Please contact your connector supplier for an appropriate connector for your particular
design. The battery pack has a “+” symbol on the lower right side of the connector
area which corresponds to pin 1 as defined in Section 3.2 and a “-” symbol on the left
end of the connector area. As mentioned in Section 3.4.1, the outer two blades of the
male connector are longer than the other 7 pins to allow first contact as the battery
pack connector is inserted into the male connector to provide ESD paths to the power
rails.

32 Design Guide
Mechanical Design Requirements

4.5 Cosmetic Battery Cover

Because the CBB Battery Pack is intended to be used with multiple chassis, it has been
designed to accept an interchangeable outer plastic cosmetic battery cover. The
design of the cover must conform to the design rules outlined in a later section, but
allows designers to customize the pack for their particular chassis design. The cover
also allows for simplified pack stocking options. The cosmetic battery cover should
never be assembled to the battery pack with permanent adhesive because this
operation will damage both the pack and the cosmetic cover during disassembly. The
pack can be used with or without this cover. The basic color for all the battery packs
without the cover is Black, Pantone C, gloss 3 ± 1. The texture is MT11015 and
applied on the surfaces as indicated in Figure 26 and Figure 27 for 6-Cell and 9-Cell
(In-Line) respectively. The texture for the 9-Cell (Triangular) BP is applied on the
surfaces shown in Figure 28 and it is MT11015 or MT11020. .

Figure 26. Texture Surfaces (6-Cell BP)

Texture

Texture

Figure 27. Texture Surfaces (9-Cell, In-line, BP)

Texture

Design Guide 33
 Mechanical Design Requirements

Figure 28. Texture Surfaces (9-Cell, Triangular, BP)

Texture

34 Design Guide
Mechanical Design Requirements

Adding the cosmetic battery pack cover can increase the overall thickness of the pack,
depending on the design. A typical cosmetic cover for 6-cell BP is shown in Figure 29.
Figure 30 and Figure 31 show cosmetic covers for 9-cell, In-Line and Triangular
respectively.

Figure 29. Wrap Around Cover (6-cell)

Figure 30. Extended Wrap around Cover (9-Cell in-line)

Figure 31. Extended Wrap around Cover (9-Cell Triangular)

Design Guide 35
 Mechanical Design Requirements

4.5.1 Cosmetic Battery Cover Catch Points

The CBB Battery Pack is designed such that the cosmetic battery cover can be
snapped onto the pack utilizing five catch points on the upper rear side of the pack (6-
cell and 9-cell Triangular) and four points on the lower front side of the pack.
Figure 32, Figure 33 and Figure 34 show the interface features for 6-cell 9-cell (Line-
In) and 9-Cell (Triangular) respectively. When no cosmetic battery cover is utilized,
the rear catch point holes can be covered with a cosmetic label, see Figure 35.

Figure 32. Cosmetic Cover Interface Features for 6-Cell BP

Interface Features for Cosmetic Cover

36 Design Guide
Mechanical Design Requirements

Figure 33. Cosmetic Cover Interface Features for 9-Cell (In-Line) BP

Interface Features for Cosmetic Cover

Figure 34. Cosmetic Cover Interface Features for 9-Cell (Triangular) BP

Interface Features for ID Cover

Design Guide 37
 Mechanical Design Requirements

Figure 35. Battery Pack without Cosmetic Battery Cover (Rear Catch Points Covered by
Label)

Safety Label

Cosmetic Label

4.5.2 Cosmetic Battery Cover Installation and Removal

IMPORTANT: To install the cosmetic battery cover, first make sure that the rear attach
points on the battery pack are visible (only applies to 6-cell and 9-cell Triangular
Battery Packs). If a label is attached over this area, please remove the label before
installing the cosmetic battery cover.

4.5.2.1 6-Cell BP
Line up the rear attach features on the inside of the cosmetic battery cover with the
corresponding attach openings on the back of the battery pack. Gently push the rear
of the cover against the battery pack until the two surfaces are flush, illustrated as
action number one in Figure 36. While holding the cover in place, push up on the
bottom of the cover until the cover snaps in place on both sides, illustrated as action
number two in Figure 36. Figure 36 shows the installation of the cosmetic cover on
the 6-cell BP.

38 Design Guide
Mechanical Design Requirements

Figure 36. Installation Process for 6-Cell Cosmetic Battery Cover

To remove the cosmetic battery cover insert a small straight-edge screw driver into
the indent on the cosmetic battery cover and gently pry back at location number one
as shown in Figure 37 and Figure 38 below. Great care should be taken when using
the screw driver because the plastic cosmetic cover can be easily damaged. There are
four indents, one for each of the four front snaps. Pry back on the cosmetic battery
cover for each of the four snaps. Rotate the cover back slightly, exposing a small gap
at location number two. Use the small screw driver to gently pry back the cosmetic
battery cover per action number two.

Figure 37. Removal Indents for 6-Cell CBB Battery Pack

Screwdriver
locations (Right
side)

Design Guide 39
 Mechanical Design Requirements

Figure 38. Removal Process for 6-Cell Cosmetic Battery Cover

Another way to remove the cosmetic cover is by utilizing a custom plastic extraction
tool. This tool has a ramp feature at its bottom edge and a reference drawing for it is
shown in Figure 41. In order to use this tool, first position it between the screwdriver
slots as shown in Figure 40. Then push the extraction tool downward as shown in
Figure 41. As the insertion tool gets wedged between the cosmetic cover and the
battery pack wall, the ramp feature on the extraction tool lifts the cosmetic cover
away from the battery pack wall and causes the two snaps from the cosmetic cover to
disengage. Repeat this procedure on the other side of the battery pack in position
one of Figure 38. Pry back on the cosmetic battery cover for each of the four snaps.
Rotate the cover back slightly, exposing a small gap at location number two. Use a
small screw driver to gently pry back the cosmetic cover per action number two.

Figure 39. Extraction Tool Reference Drawing

6
R12.67

16.36

25.34

40 Design Guide
Mechanical Design Requirements

Figure 40. Extraction Tool Reference Positioning

Extraction Tool

Screw Driver Slots

Design Guide 41
 Mechanical Design Requirements

Figure 41. Extraction Tool Motion

Ramp Feature

4.5.2.2 9-Cell (In-Line) BP

The installation of the cosmetic cover on the 9-Cell In-Line BP is shown in Figure 42.
The sequence of actions that is needed to take place during the installation is shown in
Figure 43.

While holding the cover in place, push up on the bottom of the cover until the cover
snaps in place on both sides, illustrated as action number two in Figure 43.

42 Design Guide
Mechanical Design Requirements

Figure 42. Installation Process of 9-Cell (In-Line) Cosmetic Battery Cover

Figure 43. Sequence of Actions for 9-Cell (In-Line) Cosmetic Battery Cover Installation

To remove the cosmetic battery cover from the battery pack the reversed sequence of
actions is executed as shown in Figure 44. Action number one can be performed by
either procedure using the flat blade screwdriver or the extraction tool as was
discussed previously in Section 4.5.2.1

Once the four snaps at the front are disengaged, carefully rotate and bend the cover
to clear the bottom of the battery pack and slide the cover off the rear of the battery
pack.

Design Guide 43
 Mechanical Design Requirements

Figure 44. Sequence of Actions for 9-Cell (In-Line) Cosmetic Battery Cover Removal

1
2

4.5.2.3 9-Cell (Triangular) BP

The installation of the cosmetic cover on the 9-Cell Triangular BP is shown in Figure
45. The sequence of actions that is needed to take place during the installation is
shown in Figure 46.

While holding the cover in place, push up on the bottom of the cover until the cover
snaps in place on both sides, illustrated as action number two in Figure 46.

Figure 45. Installation Process of 9-Cell (Triangular) Cosmetic Battery Cover

44 Design Guide
Mechanical Design Requirements

Figure 46. Sequence of Actions for 9-Cell (Triangular) Cosmetic Battery Cover
installation

To remove the cosmetic battery cover from the battery pack the reversed sequence of
actions is executed as shown in Figure 47. Action number one can be performed by
either procedure using the flat blade screwdriver or the extraction tool as was
discussed previously in Section 4.5.2.1

Once the four snaps at the front are disengaged, rotate and bend the cover to clear
the bottom of the battery pack. Rotate the cover back slightly, exposing a small gap
at location number two. Use a small screw driver to gently pry back the cosmetic
cover per action number two.

Figure 47. Sequence of Actions for 9-Cell (Triangular) Cosmetic Battery Cover Removal

Design Guide 45
 Mechanical Design Requirements

4.5.3 Cosmetic Battery Cover Geometry

There are three primary form factors for the cosmetic battery cover. These are the 6-
cell, the 9-cell (In-Line) and the 9-cell (Triangular) Versions. These are illustrated in
Figure 48, Figure 49 and Figure 50 respectively. Each cosmetic battery cover can be
specific and unique per the aesthetic system industrial design requirements.

Figure 48. Example of a 6-Cell Cosmetic Battery Cover

Figure 49. Example of a 9-Cell (In-Line) Cosmetic Battery Cover

46 Design Guide
Mechanical Design Requirements

Figure 50. Example of a 9-Cell (Triangular) Cosmetic Battery Cover

Design Guide 47
 Mechanical Design Requirements

The recommended maximum wall thickness for the cosmetic battery cover including
cosmetic features is 1.9 mm. Figure 51 and Figure 52 below show some critical to
function dimensions and associated tolerances for the 6-cell cosmetic battery cover.

Figure 51. Cosmetic Battery Cover Geometry for 6-Cell (Page 1 of 2)

0.5 36.3 115.4 36.3 0.7

+0.1
206 -0.3

47 47 47 47

5 X5

103.03

48 Design Guide
Mechanical Design Requirements

Figure 52. Cosmetic Battery Cover Geometry for 6-Cell (Page 2 of 2)

0.7 X4

1.5 X4

0.6 X5

.3
R0
0À B 1.8 X5
;¦ 5:1
0À A
;¦ 5:1

detail A
1.8
detail B
1.5
+0.1
+0.3
16.4

22.3

40.6
R5
1.8

+0.1
43.9
.3

-0.3

Design Guide 49
 Mechanical Design Requirements

Figure 53 and Figure 54 below show some critical to function dimensions and
associated tolerances for the 9-cell, In-Line cosmetic battery cover.

Figure 53. Cosmetic Battery Cover Geometry for 9-Cell, In-Line (Page 1 of 2)

0.7 36.3 115.4 36.3

208
A

A
+0.1
206 -0.3

50 Design Guide
Mechanical Design Requirements

Figure 54. Cosmetic Battery Cover Geometry for 9-Cell, In-Line (Page 2 of 2)

0.7

1.5
A
4:1

59.4
3.85

1.5

25.2
default A
1.8

4.7

62.7

SECTION A-A

Design Guide 51
 Mechanical Design Requirements

Figure 55, Figure 56 and Figure 57 below show some critical to function dimensions
and associated tolerances for the 9-cell, Triangular cosmetic battery cover.

Figure 55. Cosmetic Battery Cover Geometry for 9-Cell, Triangular (Page 1 of 3)

0.2
0.2
0.2

0.2

188
141

2X
47

94
0
R3.59 0.05 R3.59 0.05
2X -A- 2X 19.55 0.15
2X

7.96 0.1
2X

22.6 0.15
2X

0
-B-

R3.57 0.05 R3.57 0.05

0.1

0.2

0.2

0.2
9 0.15

2X 2X
4.7

36.3

151.7

183.3
0

-A-

SEE DETAIL

-C-

4.2 0.05

R3.4 0.05

43.19 0.2 103.02 0.2 10.69 0.15

R8.1
+0.1
206
-0.3

52 Design Guide
Mechanical Design Requirements

Figure 56. Cosmetic Battery Cover Geometry for 9-Cell, Triangular (Page 2 of 3)

0.15

0.1

0.15

0.15

0.15
0.15

0.15
0
16.91

26.43
36.5

40.6
0

R4 0.05
SEE DETAIL B

16.2 0.15
SEE DETAIL A 5X

4 0.05

4.2 0.05 4.85 0.05

R3.4 0.05 R4.4 0.05
10.69 0.15 16.04 0.15

R8.1 0.05 R3.6 0.05

0.05

0.15
2.31

39.01
0

Design Guide 53
 Mechanical Design Requirements

Figure 57. Cosmetic Battery Cover Geometry for 9-Cell, Triangular (Page 3 of 3)

2.6 0.05

0.7 0.05
1.37 0.05

1 0.05
0.6 0.05

1.8 0.05

DETAIL A DETAIL B
SCALE 5.000 SCALE 5.000
4X 5X

Ergonomic ID features can be implemented on cosmetic battery covers. This feature is

at the bottom of the cosmetic battery cover and its function is to be utilized as an
ergonomic handle so a user can more easily pull the battery pack out of a system
when it is at an installed position. This ergonomic handle is not a requirement on the
battery pack case. Figure 58 shows the ergonomic ID features on a cosmetic battery
cover for a 6 cell design. This is only one example of a typical ergonomic ID feature.

Figure 58. Ergonomic ID Feature (with Cosmetic Battery Cover Case)

Ergonomic features

54 Design Guide
Additional Information

5 Additional Information
The website http://www.mobileformafactors.org is the location for the latest
information regarding CBBs with links to industry specifications, lists of CBB-candidate
ingredients and CBB compliant ingredients, as well as links to system designers and
ingredient suppliers.

Design Guide 55
 Additional Information

56 Design Guide