Variable layer thickness in curved battery cells

Abstract

Examples related to curved batteries are disclosed herein. One example provides a battery including: an anode disposed on an anode substrate; a cathode disposed on a cathode substrate, the anode substrate being curved with a first curvature, and the cathode substrate being curved with a second curvature; and a separator between the anode and the cathode. The thickness of the anode substrate and the thickness of the cathode substrate are determined based on the curvature of the respective substrates, such that the substrate having a greater curvature of the anode substrate and the cathode substrate has a greater thickness.

Description

[0001] This application is a divisional application of a Chinese invention patent application with an international application date of August 22, 2017, a national application number of 201780050315.9, and an invention name of “Variable layer thickness in curved battery cells”. Background Art

[0002] Typical portable electronic devices utilize batteries to enable operation without being connected to a main power source. The battery may be adapted to the housing of the portable electronic device to achieve a desired package size and / or form factor for the portable electronic device. Summary of the invention

[0003] Examples related to curved batteries are disclosed herein. One example provides a battery including: an anode disposed on an anode substrate; a cathode disposed on a cathode substrate, the anode substrate being curved with a first curvature and the cathode substrate being curved with a second curvature; and a separator between the anode and the cathode. The thickness of the anode substrate and the thickness of the cathode substrate are determined based on the curvature of the respective substrates, such that the substrate having a greater curvature of the anode substrate and the cathode substrate has a greater thickness.

[0004] This summary is provided to introduce a selection of concepts in simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that address any or all of the disadvantages stated in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1A -B show a front view and a side view, respectively, of an example portable electronic device.

[0006] Figure 2 An example portable electronic device in the form of a head mounted display device is shown.

[0007] Figure 3 A cross-sectional view of an example battery is shown.

[0008] Figure 4 A cross-sectional view of an example battery including four cells is shown.

[0009] Figure 5 A flow chart illustrating a method of manufacturing a battery is shown. DETAILED DESCRIPTION

[0010] As described above, typical portable electronic devices utilize batteries to enable operation without being connected to a main power source. In order to achieve a desired package size and / or form factor for the portable electronic device, the battery can be adapted to the housing of the portable electronic device. For example, the size of the battery can be limited to accommodate the package size of the portable electronic device. Alternatively or additionally, the geometry of the battery can be configured to accommodate the form factor of the portable electronic device, which in some implementations can assume a curved shape, such as those of a curved smartphone or a curved smart watch.

[0011] The manufacturing process for a battery configured for a portable electronic device having a curved form factor may attempt to bend the battery. However, following the electrode formation and stacking process for the curved electrode layer in such a battery, the material in the electrode layer may exhibit elasticity and at least partially return to the initial shape (e.g., return to a planar shape from before bending). Such elasticity may be the result of residual stress and / or strain in the electrode material that has accumulated during the bending of the planar layer, for example, which is released over time, thereby causing the overall battery including the electrode material to deflect and lose curvature and return to a more planar shape. The deflection of the battery may compete with the form factor of the portable electronic device for which the battery is configured, for example, by the housing of the contact device, which potentially results in a degraded operation of the battery and / or the portable electronic device.

[0012] Thus, examples related to batteries and battery manufacturing methods are disclosed. As described in more detail below, a battery may include: an anode disposed on an anode substrate; a cathode disposed on a cathode substrate, the anode substrate being bent at a first curvature and the cathode substrate being bent at a second curvature; and a separator between the anode and the cathode. The thickness of the anode substrate and the thickness of the cathode substrate may be determined based on the curvature of the respective substrates, such that the substrate having a greater curvature of the anode substrate and the cathode substrate has a greater thickness.

[0013] Figure 1A A front view of a portable electronic device 100 is shown. The device 100 is shown in the form of a smart phone, but may assume any other suitable form factor, including but not limited to a tablet computing device, a laptop computing device, a wearable electronic device, etc. The device 100 includes a display 102 and a display device (not shown). Figure 1A Suitable computing device hardware (e.g., processor, memory) for performing various computing device functions, such as controlling display output based on user input (e.g., received via a touch screen of the portable electronic device and / or via another suitable mechanism).

[0014] like Figure 1B, which shows a side view of a portable electronic device 100 that includes a curved form factor. In particular, the device 100 includes a housing 104 having a curved portion 106, whose curved geometry can be accommodated by various curved components arranged therein. To this end, the display 102 can be curved, and the battery 108 is arranged in the curved portion 106 and electrically coupled to the display and / or other potential components for enabling portable powered operation of the device 100. As described in more detail below, the battery 108 may include two or more cells coupled together (e.g., in parallel or in series) to increase the voltage and / or current provided to the device 100. The thickness of each cell can fall within various suitable ranges (such as between 5μm and 40μm, or more particularly between 10μm and 20μm). With the thickness of each cell being between 10 μm and 20 μm, for example, the total thickness of two cells integrated into the battery 108 may be between 20 μm and 40 μm, the total thickness of three cells may be between 30 μm and 60 μm, and the total thickness of four cells may be between 40 μm and 80 μm, etc. Regardless of the number of cells included therein, the battery 108 may support a thin and compact form factor of the device 100. Further, the battery 108 may be replaceable and / or rechargeable.

[0015] Battery 108 can accommodate the curved form factor of other portable electronic devices. As another example, Figure 2 A portable electronic device in the form of a head mounted display (HMD) device 200 is shown. The HMD device 200 includes a frame 202 that includes a strap that can be worn around the wearer's head, wherein the frame supports a see-through display component that is positioned near the wearer's eyes. The HMD device 100 can utilize augmented reality technology to enable simultaneous viewing of a virtual display image and a real-world background. In this way, the HMD device 200 can generate virtual images via a see-through display system (including a see-through mask 206). A controller 208 is operatively coupled to the see-through display system and other display components. The controller 208 includes one or more logic devices and one or more storage devices that maintain instructions executable by the (one or more) logic devices to enact various functions of the HMD device 200. The HMD device 200 may also include other components, such as a two-dimensional image camera 210 (e.g., a visible light camera and / or an infrared camera) and a depth camera 212, as well as other components not shown in FIG. Figure 2 Other potential components in the device include, but are not limited to, speakers, microphones, accelerometers, gyroscopes, magnetometers, temperature sensors, touch sensors, biometric sensors, other image sensors, gaze detection systems, communication facilities, and GPS receivers.

[0016] Figure 2 The battery 108 is shown disposed in a curved portion 214 of the frame 202 for enabling portable powered operation of the HMD device 200. The curved geometry of the battery 108 accommodates the curved portion 214 so that the curved portion can receive the battery 108 without sacrificing the desired package size, compact form factor, wearability, and aesthetic quality of the HMD device 200. As described above, the battery 108 can include two or more cells to increase the voltage and / or current provided to the HMD device 200, and can be replaceable and / or rechargeable. Further, although not shown in Figure 2 , but two or more batteries 108 may be included in the device 200 (e.g., at other curved portions of the frame 202). Still further, the battery 108 may be included in other devices, such as those that include a housing with curved and planar portions (e.g., a smart watch).

[0017] Figure 3 is a cross-sectional view of a battery 108. As shown therein, the battery 108 includes various curved layers 302 that are formed in a process that reduces residual stress and / or strain and thus allows the curved geometry of the layer to be maintained when installed in a device, which reduces its tendency to deform to an initial (e.g., planar) shape. Figure 5 An example method of manufacturing a battery according to the methods described herein is described.

[0018] Layer 302 includes: an anode 304, which is arranged on an anode substrate 306; a cathode 308, which is arranged on a cathode substrate 310; and a separator 312, which is between the anode and the cathode for electrically isolating the anode and the cathode. As an example, the anode 304 may include a graphite composite material mixed with other (one or more) chemicals forming a paste applied to the anode substrate 306, which may include copper (e.g., copper foil). For example, the thickness of the anode substrate 306, for example, as measured along the radial direction R, may be between 2 μm and 18 μm, or may be 12 μm. The cathode 308 may include lithium cobalt oxide (LiCoO2) in the form of a paste applied to the cathode substrate 310, which may include aluminum (e.g., aluminum foil). Other suitable materials may be used alternatively. For example, the thickness of the cathode substrate 310, for example, as measured along the radial direction R, may be between 4 μm and 26 μm, or between 22 μm and 26 μm, or may be 24 μm. The separator 312 may include polyethylene and / or polypropylene - for example, as a layer coated on both sides with aluminum oxide.

[0019] The thickness of each layer 302 may be determined by the curvature of the layer. More specifically, a layer 302 having a greater curvature relative to another layer may have a greater thickness than the other layer. To this end, Figure 2 An anode substrate 306 curved with a first curvature and a cathode substrate 310 curved with a second curvature are shown, wherein the second curvature is greater than the first curvature. In this arrangement, the anode substrate 306 may have a radius of curvature greater than the radius of curvature of the cathode substrate 310, which may share a common center of curvature with the anode substrate and may be separated from the center of curvature by a radial distance R1 (not shown in FIG. 1 ) than the anode substrate 306. Figure 3 The smaller radial distance R2 (not shown in Figure 3 However, implementations are contemplated in which the first curvature of the anode substrate 306 is greater than the second curvature of the cathode substrate 310. In general, as each layer 302 penetrates with a greater curvature, the thickness of that layer increases. As such, the ratio of the thickness of a given layer 302 to the curvature of that layer can remain substantially constant throughout variations in the thickness and curvature of that layer. Further, although Figure 3 While an example is depicted in which the thickness of each layer 302 remains substantially constant throughout a cross-section of the battery 108—e.g., as measured along the circumferential direction C—implementations in which the thickness of one or more of the layers varies along the circumferential direction C are possible—e.g., to support a tapered device housing. A layer having a variable thickness along the circumferential direction C may be thicker or thinner toward the middle relative to its ends, or may exhibit any other suitable type of thickness variation.

[0020] The thickness of one layer 302 may be different than the thickness of another layer. In one example, the unequal layer thicknesses may be a result of the manufacturing process of the battery 108 and the fact that the layers 302 are elongated in a curved manner for particular portions thereof. In this example, the layers 302 may initially have substantially equal lengths and / or thicknesses (e.g., and may be planar). Following the elongation, the layers 302 that are more radially outward may be longer than the layers that are more radially inward—e.g., as in Figure 3 As shown in , the arc length of the anode substrate 306 along the circumferential direction C is greater than the arc length of the cathode substrate 310 along the circumferential direction. Being extended to a relatively greater extent than the cathode substrate 310, the thickness of the anode substrate 306 may be smaller than the thickness of the cathode substrate. Therefore, the thickness of the anode 304 may be smaller than the thickness of the cathode 308.

[0021] Figure 3 Thicknesses t1, t2, t3, t4, and t5 are shown for layers 306, 304, 312, 308, and 310, respectively. One or more of the thicknesses t1-t5 may be substantially equal, including all of the thicknesses in some embodiments, or each thickness may be different from the other thicknesses in other examples. Figure 3 In the example shown in , thicknesses t1 and t5 are different from each other, and thicknesses t2 and t4 are different from thicknesses t1, t3, and t5. For example, thicknesses t2 and t4 may be substantially the same.

[0022] Unequal thicknesses between or among the layers 302 can support desired material and / or mechanical properties of the layers and the battery 108. More particularly, one or more layers 302 can be saturated with different thicknesses to accommodate different types of pressures and / or strains. For example, a more radially outward layer 302 (such as the anode substrate 306) can be relatively thinner than one or more radially inward layers, such that the more radially outward layers can withstand elongation without degradation. As another example, a more radially inward layer 302 (such as the cathode substrate 310) can exhibit a greater degree of strain relative to one or more radially outward layers and can stiffen after compression (as part of bending the battery 108), thereby reducing the tendency of these layers to return to an initial (e.g., planar) shape before bending.

[0023] As described above, a battery manufactured according to the methods described herein may include two or more cells coupled in series or in parallel. Figure 4 A cross-sectional view of a battery 400 including four cells 402 connected in parallel is shown. For example, one or more of the cells 402 may be the battery 108. The battery 400 includes: a plurality of anodes 404, each disposed on a corresponding anode substrate 406; a plurality of cathodes 408, each disposed on a corresponding cathode substrate 410; and a plurality of separators 412, each disposed between corresponding anode-cathode pairs. The battery 400 also includes a plurality of anode tabs 414, each coupled to a corresponding anode 404 of a corresponding cell 402. Each anode tab 414 may serve as an anode terminal for its corresponding cell 402, and may be coupled together with other anode tabs to form a battery anode tab 416 of the battery 400. Similarly, the battery 400 also includes a plurality of cathode tabs 418, each coupled to a corresponding cathode 408 of a corresponding cell 402. Each cathode tab 418 may function as a cathode terminal for its corresponding cell 402 and may be coupled together along with other cathode tabs to form a battery cathode tab 420 for the battery 400 .

[0024] use Figure 4 , the cells 402 may be connected in parallel or in series to provide a common anode tab 416 and cathode tab 420 of the battery 400, which may be connected to a load to form a power supply circuit. Figure 4 The diagram schematically depicts a load L connected to a battery anode tab 416 and a cathode tab 420, and may represent the portable electronic device 100 of FIG. 1 , Figure 2One or more components of the HMD device 200, or any other suitable component of the device to which power is desired. Although shown as contacts, the battery anode tab 416 and cathode tab 420 may assume any suitable form and may be arranged at any suitable location at the battery 400.

[0025] Although the anode 404 of the cell 402 and the cathode 408 of the cell may be coupled together, as described above, other portions of the cell may be physically and / or electrically isolated from those of another cell. To this end, Figure 4 A corresponding insulator 422 is shown for each unit 402. The insulator 422 can be implemented in various suitable ways. As an example, the housing 424 that can at least partially seal the unit 402 can include an inner polypropylene coated on metal. As another example, the unit 402 can be rolled onto polypropylene and then inserted into the housing 424.

[0026] The housing 424 may be formed according to various suitable processes. As one example, the housing 424 may be initially formed as a rectangular housing that is subsequently deformed to achieve a curved shape. Figure 4 As shown in FIG. 4 , the housing 424 may have a tapered shape to accommodate the lower width of the more radially inwardly positioned cells 402 (e.g., toward the Figure 4 As other examples, housing 424 may be punched, stamped, or formed from two or more initially separate pieces that are then joined together in a suitable process, such as welding.

[0027] The thickness of each cell 402 can be determined by the curvature of the cell, and both the thickness and curvature of the cell can increase as the battery 400 traverses radially inward. For example, the thickness of cell 402D, which is radially farther inward than cell 402C, can be greater than the thickness of cell 402C. Further, the curvature of cell 402D can be greater than the curvature of cell 402C. Therefore, the thickness of a given layer in cell 402 can be different from the thickness of a corresponding layer in another cell. For example, the thickness of separator 412D can be greater than the thickness of separators 412A-C. The thickness of separator 402 can increase as the separator becomes more curved, although thicker separators can be provided to accommodate, for example, thicker electrode pastes.

[0028] As an example, the thickness of cathode substrate 410A may be 10 μm, the thickness of cathode substrate 410B may be 11 μm, the thickness of cathode substrate 410C may be 12 μm, and the thickness of cathode substrate 410D may be 14 μm. The ratio of the thickness increase with increasing curvature may be constant or may increase, and may be linear or nonlinear. As another example, the radius of curvature of cell 402A (e.g., the average radius of curvature or the radius of curvature at a radially intermediate cell position) may be 200 mm, the radius of curvature of cell 402B may be 175 mm, the radius of curvature of cell 402C may be 150 mm, and the radius of curvature of cell 402D may be 100 mm. Thus, the curvature of cell 402D may be 1 / 100 mm, the curvature of cell 402C may be 1 / 150 mm, the curvature of cell 402B may be 1 / 175 mm, and the curvature of cell 402A may be 1 / 200 mm. Thus, it will be appreciated that a substrate having a greater curvature may have a greater thickness. In this example, adjacent cells 402 may be separated by different amounts of distance with greater separation towards the edge of the cell. The ratio of the radii of curvature may be constant or may increase, and may be linear or non-linear.

[0029] As another example, the thickness of cell 402A may be 5 mm, the thickness of cell 402B may be 5.5 mm, the thickness of cell 402C may be 6 mm, and the thickness of cell 402D may be 7 mm. In this example, the radius of curvature of cell 402A may be 400 mm, the radius of curvature of cell 402B may be 350 mm, the radius of curvature of cell 402C may be 300 mm, and the radius of curvature of cell 402D may be 200 mm. Moreover, in this example, it will be understood that cells with a larger curvature (i.e., a smaller radius of curvature) may have a larger thickness. In this example, adjacent cells 402 may be separated by different amounts of distance with a greater separation toward the edges of the cells. It will be understood that these specific thicknesses and curvatures are presented as examples only, and many other thickness values ​​may be employed that change the thickness of the cells so that cells with a higher (larger) curvature are made thicker than cells with a lower (smaller) curvature.

[0030] While in some implementations the total thickness may vary between cells, and potentially between corresponding layers across different cells, the curvature-to-thickness ratios of the layers across different cells may be substantially equal. For example, the ratio of the curvature of the anode of a first anode-cathode pair (e.g., anode 404A of cell 402A) to the thickness of the corresponding first anode substrate (e.g., anode substrate 406A of cell 402A) may be substantially equal to the ratio of the thickness of the anode of a second anode-cathode pair (e.g., anode 404B of cell 402B) to the thickness of the corresponding second anode substrate (e.g., anode substrate 406B of cell 402B). Similarly, the ratio of the curvature of the cathode of a first anode-cathode pair (e.g., cathode 408A of cell 402A) to the thickness of the corresponding first cathode substrate (e.g., cathode substrate 410A of cell 402A) may be substantially equal to the ratio of the thickness of the cathode of a second cathode-cathode pair (e.g., cathode 408B of cell 402B) to the thickness of the corresponding second cathode substrate (e.g., cathode substrate 410B of cell 402B). In some examples, similar substantially equal ratios may be exhibited for other layers in unit 402 .

[0031] Various modifications to the battery 400 are contemplated. For example, the cells 402 may be connected in series, alternatively or in addition to being connected in parallel. Further, Figure 4 The four cells 402 shown in FIG. 4 are provided as an example, and any suitable number of cells may be used to implement the battery 400 .

[0032] Figure 5 1 is a flow chart illustrating a method 500 for manufacturing a battery. For example, the method 500 may be used to manufacture the battery 108 ( Figure 3 ) and / or battery 400( Figure 4 ).

[0033] At 502, method 500 includes manufacturing two substrates to form an anode substrate and a cathode substrate. For example, the anode substrate may be Figure 3 The anode substrate 306, and the cathode substrate may be Figure 3 The cathode substrate 310 of FIG. 4 . The anode substrate may be curved at a first curvature, and the cathode substrate may be curved at a second curvature. One of the anode substrate and the cathode substrate having a larger curvature may have a larger thickness. For example, the first curvature may be greater than the second curvature, in which case the anode substrate may have a greater thickness than the cathode substrate. Alternatively, the second curvature may be greater than the first curvature, in which case the cathode substrate may have a greater thickness than the anode substrate. For example, the thickness of the anode substrate may be between 2 μm and 18 μm, and the thickness of the cathode substrate may be between 4 μm and 26 μm. The anode substrate may include copper or nickel (e.g., copper or nickel foil), and the cathode substrate may include aluminum (e.g., aluminum foil).

[0034] In some examples, manufacturing two substrates may include annealing the two substrates. As the grade of the substrate material, and the operating conditions associated with annealing the substrate may affect its tensile strength, these parameters may be selected to achieve the desired tensile strength of the substrate material. In order to increase the residual strength of the substrate material, a cold rolled foil may be used, or the substrate material thickness may be increased. The annealing process may be implemented in various suitable ways and may include applying a relatively high temperature to the substrate material, quenching the substrate material, and preventing the substrate material from returning to, for example, an initial (e.g., planar) shape.

[0035] At 504, method 500 includes disposing an anode on an anode substrate. For example, the anode may be Figure 3 Anode 304. The anode arrangement may include coating the anode substrate with an anode, which in some examples may be a paste including a graphite composite mixed with other chemicals. In some examples, the anode arrangement may include curing the anode paste.

[0036] At 506, method 500 includes disposing a cathode on a cathode substrate. For example, the cathode may be Figure 3 The cathode 308. The cathode arrangement may include coating the cathode substrate with the cathode, which in some examples may be a paste including LCO. In some examples, the cathode arrangement may include curing the cathode paste.

[0037] At 508, method 500 includes isolating the anode from the cathode using a separator. For example, the separator may be Figure 3 The separator 312. The separator may be a composite having various layers of polyethylene coated on both sides with aluminum oxide.

[0038] At 510, method 500 includes providing tabs coupled to the anode and cathode, respectively. For example, one of anode tabs 414A-D may be coupled to Figure 4 anode, and one of the cathode tabs 418A-D may be coupled to Figure 4 cathode.

[0039] In some examples, the battery may be one of a plurality of cells manufactured according to method 500. In this case, method 500 may also include coupling together each of the tabs coupled to the anode of the respective cell to form a battery anode tab, and coupling together each of the tabs coupled to the cathode of the respective cell to form a battery cathode tab. For example, the battery anode tab may be Figure 4 The battery anode tab 416 and the battery cathode tab may be Figure 4 The battery cathode tab 420. In other examples, the cathode tab of one cell can be coupled to the anode tab of another cell to achieve a series cell configuration.

[0040] The thickness of the first unit formed by the first anode-cathode pair, the first anode substrate, the first cathode substrate and the first separator may be greater than the thickness of the second unit formed by the second anode-cathode pair, the second anode substrate, the second cathode substrate and the second separator, and the curvature of the first unit is greater than the curvature of the second unit. The first unit may be relatively more radially inward than the second unit - for example, the first unit and the second unit may be displaced from a common center of curvature by radii R1 and R2, respectively. The thickness of one or more of the layers may be between the first unit and the second unit (such as the separator thickness). The thickness of the first unit and the second unit may be substantially constant or may vary throughout the cross section (for example, in the circumferential direction). The ratio of the curvature of the anode of the first anode-cathode pair to the thickness of the first anode substrate may be substantially equal to the ratio of the curvature of the anode of the second anode-cathode pair to the thickness of the second anode substrate, and the ratio of the curvature of the cathode of the first anode-cathode pair to the thickness of the first cathode substrate may be substantially equal to the ratio of the curvature of the cathode of the second anode-cathode pair to the thickness of the second cathode substrate.

[0041] At 512, method 500 may optionally include manufacturing a housing for the battery. For example, the housing may be Figure 4 The housing 424. The housing may be formed in any suitable manner, which may include deforming a rectangular container to obtain a curved shape, stamping the housing, separately forming two or more parts of the housing and bonding the parts together (e.g., via welding). The housing may have a tapered shape (e.g., narrower at the bottom of the housing than at the top).

[0042] At 514 , method 500 may optionally include placing a battery in the housing.

[0043] The following paragraphs provide additional support for the claims of the present application. One aspect of the present disclosure provides a battery, comprising: an anode, which is arranged on an anode substrate; a cathode, which is arranged on a cathode substrate, the anode substrate is bent with a first curvature and the cathode substrate is bent with a second curvature; and a separator, which is between the anode and the cathode, wherein the thickness of the anode substrate and the thickness of the cathode substrate are determined based on the curvature of the respective substrates, so that one of the anode substrate and the cathode substrate having a larger curvature has a larger thickness. In this aspect, the thickness of the anode substrate may alternatively or additionally be between 2 microns and 18 microns. In this aspect, the thickness of the cathode substrate may alternatively or additionally be between 4 microns and 26 microns. In this aspect, the first curvature may alternatively or additionally be greater than the second curvature. In this aspect, the second curvature may alternatively or additionally be greater than the first curvature. In this aspect, the anode may alternatively or additionally be one of a plurality of anodes, each of which is disposed on a corresponding anode substrate, the cathode may alternatively or additionally be one of a plurality of cathodes, each of which is disposed on a corresponding cathode substrate, the separator may alternatively or additionally be one of a plurality of separators, each of which is disposed between a corresponding anode-cathode pair, and the battery may alternatively or additionally include: a plurality of anode tabs, each of which is coupled to a corresponding anode of the plurality of anodes, the plurality of anode tabs being coupled together to form a battery anode tab; and a plurality of cathode tabs, each of which is coupled to a corresponding cathode of the plurality of cathodes, the plurality of cathode tabs being coupled together to form a battery cathode tab. In this aspect, the thickness of a first unit formed by the first anode-cathode pair, the first anode substrate, the first cathode substrate, and the first separator may alternatively or additionally be greater than the thickness of a second unit formed by the second anode-cathode pair, the second anode substrate, the second cathode substrate, and the second separator, and the curvature of the first unit may alternatively or additionally be greater than the curvature of the second unit. In this aspect, the ratio of the curvature of the anode of the first anode-cathode pair to the thickness of the first anode substrate may alternatively or additionally be substantially equal to the ratio of the curvature of the anode of the second anode-cathode pair to the thickness of the second anode substrate, and the ratio of the curvature of the cathode of the first anode-cathode pair to the thickness of the first cathode substrate may alternatively or additionally be substantially equal to the ratio of the curvature of the cathode of the second anode-cathode pair to the thickness of the second cathode substrate. In this aspect, the thickness of the first separator may alternatively or additionally be greater than the thickness of the second separator. In this aspect, the thickness of the anode may alternatively or additionally be different from the thickness of the cathode. In this aspect, the anode substrate may alternatively or additionally include copper, and the cathode substrate may alternatively or additionally include aluminum.

[0044] On the other hand, a method for manufacturing a battery is provided, including: manufacturing two substrates to form an anode substrate curved with a first curvature and a cathode substrate curved with a second curvature, one of the anode substrate and the cathode substrate having a larger curvature has a thicker thickness, arranging the anode on the anode substrate, arranging the cathode on the cathode substrate, isolating the anode from the cathode using a separator; and providing tabs coupled to the anode and the cathode, respectively. In this aspect, the thickness of the anode substrate can alternatively or additionally be between 2 microns and 18 microns. In this aspect, the thickness of the cathode substrate can alternatively or additionally be between 4 microns and 26 microns. In this aspect, the battery can alternatively or additionally be one of a plurality of cells manufactured according to the method for manufacturing a battery, and the method can alternatively or additionally include: coupling each of the tabs coupled to the anode of the corresponding cell together to form a battery anode tab, and coupling each of the tabs coupled to the cathode of the corresponding cell together to form a battery cathode tab. In this aspect, the thickness of the first unit formed by the first anode-cathode pair, the first anode substrate, the first cathode substrate and the first separator can alternatively or additionally be greater than the thickness of the second unit formed by the second anode-cathode pair, the second anode substrate, the second cathode substrate and the second separator, and the curvature of the first unit is greater than the curvature of the second unit.

[0045] On the other hand, a portable electronic device is provided, comprising: a housing including a curved portion, a curved display, and a curved battery electrically coupled to the display, the 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, wherein the thickness of the anode substrate and the thickness of the cathode substrate are determined based on the curvature of the respective substrates, so that one of the anode substrate and the cathode substrate having a larger curvature has a larger thickness. In this aspect, the curved battery may alternatively or additionally be one of a plurality of curved batteries, and the total thickness of the plurality of curved batteries may alternatively or additionally be between 20 μm and 80 μm. In this aspect, the portable electronic device may alternatively or additionally be a smart phone, and the curved battery may alternatively or additionally be arranged in the curved portion of the housing. In this aspect, the portable electronic device may alternatively or additionally be a head-mounted display device, and the curved battery may alternatively or additionally be arranged in the curved portion of the housing.

[0046] It will be appreciated that the configuration and / or method described herein are exemplary in nature, and these specific embodiments or examples are not considered in a limiting sense, because many variations are possible. The specific routine or method described herein may represent one or more processing strategies in any number of processing strategies. Thus, the various actions illustrated and / or described may be performed in the illustrated and / or described order, in other orders, in parallel or omitted. Similarly, the order of the process described above may be changed.

[0047] The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various processes, systems and configurations, and other features, functions, acts, and / or properties disclosed herein, as well as any and all equivalents thereof.

Claims

1. A battery comprising: a first unit comprising a set of layers, the set of layers comprising an anode, a cathode, and a separator, the separator being configured to electrically isolate the anode and the cathode of the first unit, the layers of the set of layers of the first unit having a first curvature; as well as a second unit, comprising a set of layers, the set of layers comprising an anode, a cathode, and a separator, the separator being configured to electrically isolate the anode and the cathode of the second unit, the layers in the set of layers of the second unit having a second curvature, the second curvature being different from the first curvature in a cross-sectional plane defined by a radial direction and a circumferential direction, the first curvature and the second curvature being separated from a common center of curvature in the cross-sectional plane by respective radial distances along the radial direction, wherein the first cell has a first cell curvature, and wherein the second cell has a second cell curvature, the second cell curvature being different from the first cell curvature, wherein a thickness of the first cell is determined by the first cell curvature of the first cell, and wherein a thickness of the second cell is determined by the second cell curvature of the second cell, and The first unit is farther away from the common curvature center than the second unit, the second unit curvature of the second unit is greater than the first unit curvature of the first unit, and the thickness of the second unit is greater than the thickness of the first unit. 2 . The battery of claim 1 , wherein the anode and the cathode of the first cell have a substantially common curvature. 3 . The battery according to claim 1 , wherein the anode of the first cell and the anode of the second cell have different curvatures.

4. The battery of claim 1, wherein the layers in the set of layers of the first cell have a first thickness, and wherein the layers in the set of layers of the second cell have a second thickness, the second thickness being different from the first thickness. 5 . The battery of claim 1 , wherein the anode of the first cell is disposed on an anode substrate, and wherein the cathode of the first cell is disposed on a cathode substrate.

6. The battery of claim 5, wherein the anode substrate and the cathode substrate have a substantially common curvature.

7. The battery of claim 1, wherein the first cell and the second cell are electrically coupled together.

8. The battery of claim 1, wherein the thickness of the layers in the set of layers of the first cell is determined by the first curvature, and wherein the thickness of the layers in the set of layers of the second cell is determined by the second curvature. 9 . The battery according to claim 1 , wherein the first cell and the second cell are arranged in a case having a tapered shape.

10. A battery comprising: A first unit including an anode, a cathode, and a separator configured to electrically isolate the anode and the cathode of the first unit, the first unit having a first curvature; as well as a second unit, comprising an anode, a cathode, and a separator configured to electrically isolate the anode and the cathode of the second unit, the second unit having a second curvature, the second curvature being different from the first curvature in a cross-sectional plane defined by a radial direction and a circumferential direction, the first curvature and the second curvature being separated from a common center of curvature in the cross-sectional plane by respective radial distances along the radial direction, wherein a thickness of the first cell is determined by the first curvature of the first cell, and wherein a thickness of the second cell is determined by the second curvature of the second cell, and The first unit is farther away from the common curvature center than the second unit, the second curvature of the second unit is greater than the first curvature of the first unit, and the thickness of the second unit is greater than the thickness of the first unit.

11. The battery of claim 10, wherein the anode and cathode of the first cell have a substantially common curvature.

12. The battery of claim 10, wherein the anode and cathode of the first cell have a substantially common thickness. 13 . The battery according to claim 10 , wherein the first cell and the second cell are arranged in a case having a tapered shape.

14. A portable electronic device comprising: monitor; Processor and memory; as well as A battery configured to supply power to the portable electronic device, the battery comprising: a first unit comprising a set of layers, the set of layers comprising an anode, a cathode, and a separator, the separator being configured to electrically isolate the anode and the cathode of the first unit, the layers of the set of layers of the first unit having a first curvature; as well as a second unit, comprising a set of layers, the set of layers comprising an anode, a cathode, and a separator, the separator being configured to electrically isolate the anode and the cathode of the second unit, the layers in the set of layers of the second unit having a second curvature, the second curvature being different from the first curvature in a cross-sectional plane defined by a radial direction and a circumferential direction, the first curvature and the second curvature being separated from a common center of curvature in the cross-sectional plane by respective radial distances along the radial direction, wherein the first cell has a first cell curvature, and wherein the second cell has a second cell curvature that is different from the first cell curvature, wherein a thickness of the first cell is determined by the first cell curvature of the first cell, and wherein a thickness of the second cell is determined by the second cell curvature of the second cell, and The first unit is farther away from the common curvature center than the second unit, the second unit curvature of the second unit is greater than the first unit curvature of the first unit, and the thickness of the second unit is greater than the thickness of the first unit.

15. The portable electronic device of claim 14, wherein the anode and the cathode of the first cell have a substantially common curvature.

16. The portable electronic device of claim 14, wherein the layers in the set of layers of the first unit have a first thickness, and wherein the layers in the set of layers of the second unit have a second thickness, the second thickness being different from the first thickness.

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