An ultra-thin flexible safety battery, intelligent heating system and wearable article

Abstract

This invention provides an ultra-thin flexible safety battery, an intelligent heating system, and wearable devices. The ultra-thin flexible safety battery combines an extremely thin structure, a high waterproof rating, and high stability after tens of thousands of bends. Its precise performance parameters are perfectly suited to the imperceptible thickness requirements of wearable devices, adapting to dynamic bending scenarios in clothing and withstanding daily sweat and washing environments. It solves the compatibility problems of insufficient flexibility and poor waterproofing in traditional power supply components from the core power supply end. The intelligent heating system based on this battery is highly compatible with wearable scenarios, achieving system-level synergy between power supply, heating, and temperature control, improving the operational reliability of dynamic wearables. Wearable devices integrating this system eliminate the feeling of foreign objects in the power supply unit, are compatible with industrialized textile production, and allow end products to combine a comfortable wearing experience with stable heating functionality, significantly improving performance and scenario adaptability.

Description

Technical Field

[0001] This invention relates to the fields of flexible electronics, smart textiles and personal thermal management, and in particular to an ultrathin flexible safety battery, a smart heating system and wearable devices that are reverse-engineered to meet the extreme mechanical and safety requirements of flexible heated wearables. Background Technology

[0002] The industrialization of flexible heated wearables has long been limited by the lack of matching "wearable-grade" power supply solutions. As an important application area in the fields of smart textiles and personal thermal management, flexible heated wearables (including clothing, footwear, protective gear, etc.) have stringent requirements for the adaptability of power supply units. However, existing general power supply solutions are unable to meet their core needs in actual wearable scenarios, becoming a key bottleneck restricting the large-scale development of the industry.

[0003] There is a fundamental mismatch between existing technologies and the application requirements of flexible heated wearables, specifically in three dimensions: First, performance mismatch. Commercially available flexible batteries are mostly designed for consumer electronics products such as foldable screen phones. Their bending life of thousands of cycles, thickness of no less than 0.6mm, and existing packaging forms cannot adapt to the mechanical environment of tens of thousands of complex bending, rubbing, and washing throughout the entire life cycle of wearables, nor can they meet the requirement of imperceptible thickness below millimeters. Second, safety architecture mismatch. The safety design of general-purpose batteries focuses on preventing the cell itself from exploding, without considering the risk of heat spread and ignition of textiles after battery failure in close-fitting scenarios. Moreover, the traditional "battery + protection" separate solution is prone to failure during the dynamic use of wearables. Third, system integration mismatch. Simply connecting general-purpose batteries, heating films, and controllers with wires does not solve the problem of the coordinated reliability and safety of "power supply-heating-protection-control" on a dynamic flexible substrate at the system level.

[0004] In summary, existing technologies suffer from three core technical problems: First, their performance cannot match the mechanical environment and non-imperceptible thickness requirements throughout the entire lifecycle of wearable devices; second, their safety architecture is not adapted to close-fitting wear scenarios, making it difficult to prevent the risk of heat spread igniting textiles; and third, the lack of collaborative design in system integration makes it impossible to guarantee reliability and safety on dynamically flexible substrates. The root cause of these problems lies in the fact that existing solutions all adopt a passive approach of "adapting rigid power supply units to flexible wearable fabric systems," failing to design power supply solutions from the perspective of the essential needs of wearable scenarios, thus preventing a fundamental solution to the adaptation problem. Summary of the Invention

[0005] In response to the above-mentioned defects or improvement needs of existing technologies, this invention provides an ultra-thin flexible safety battery, an intelligent heating system, and wearable devices to solve the technical problems of performance mismatch, incompatible safety architecture, and poor system integration and coordination when adapting existing rigid power supply batteries to flexible wearable scenarios.

[0006] To solve the above-mentioned technical problems, the present invention first provides an ultra-thin flexible safety battery, including a flexible battery body with a thickness of 0.1 to 0.5 mm. After the flexible battery body is repeatedly bent 10,000 times with a bending radius of 5 mm and a bending angle of 120°, the capacity retention rate is ≥90% and the internal resistance increase is ≤20%.

[0007] Specifically, this ultra-thin flexible safety battery, by precisely limiting its ultra-thin thickness to 0.1-0.5mm and maintaining its electrical performance standards under harsh bending conditions, not only meets the physical requirements of seamless wearing of flexible heated wearables, but also ensures that the battery's structure and electrical performance remain stable during long-term use when clothing is dynamically bent. This significantly improves the battery's wearability, environmental tolerance, and long-term durability in flexible heated clothing applications.

[0008] Preferably, the waterproof rating of the flexible battery body is IPX7; after multiple flexible battery bodies undergo 30 cycles of 180° folding and compaction, the physical damage rate by quantity is ≤0.1%.

[0009] Specifically, the flexible battery body achieves an IPX7 waterproof rating, effectively resisting the effects of moisture from daily sweating and short-term immersion, meeting the daily waterproof requirements of wearable products. Furthermore, its excellent performance, with a physical damage rate of ≤0.1% after 30 cycles of 180° folding and compaction, demonstrates strong bending resistance and durability, making it suitable for long-term use in situations involving dynamic deformation of clothing. This ensures the structural integrity and electrical performance stability of the battery during wear, significantly improving its applicability and reliability in products such as flexible heated clothing.

[0010] Preferably, the flexible battery body includes a cell unit group, an encapsulation layer, and a first waterproof coating layer; the encapsulation layer completely wraps around and adheres to the outer surface of the cell unit group, and the first waterproof coating layer completely wraps around and adheres to the outer surface of the encapsulation layer.

[0011] The battery cell unit group includes multiple battery cell units arranged side by side and connected in series. The battery cell unit is a polymer gel lithium-ion battery cell or a solid lithium-ion battery cell. The encapsulation layer is a flexible aluminum-plastic film. The material of the first waterproof coating layer is selected from one of ePTFE (expanded polytetrafluoroethylene), TPU (thermoplastic polyurethane), or PU (polyurethane).

[0012] In another embodiment, the flexible battery body only includes a cell unit group and an encapsulation layer; in this case, the flexible battery body does not have waterproof performance.

[0013] Specifically, polymer gel lithium-ion cells or solid-state lithium-ion cells are paired with a flexible aluminum-plastic film encapsulation layer, ensuring both basic protection and structural stability of the cells without compromising overall battery flexibility. The outer first waterproof coating layer, made of ePTFE, TPU, or PU, combines excellent waterproofing with flexible adaptability, effectively preventing moisture intrusion. The overall structure is suitable for the dynamic bending scenarios of wearable devices while resisting the effects of daily sweat and minor water immersion, significantly improving battery safety, structural durability, and wearability, providing reliable power supply for products such as flexible heated clothing.

[0014] Preferably, the ultrathin flexible safety battery also includes a thermal expansion protection layer integrally formed with the flexible battery body, and the thermal expansion protection layer is disposed on at least one outer surface of the flexible battery body with the largest area. The thermal expansion protective layer includes a substrate and thermal expansion microcapsules uniformly dispersed in the substrate. The thermal expansion microcapsules expand when heated and undergo an endothermic phase change. The trigger expansion temperature T is 70℃~80℃, which is greater than the maximum operating temperature of the flexible battery body.

[0015] Specifically, this ultra-thin flexible safety battery integrates a thermal expansion protection layer on the outside of the flexible battery body and precisely calibrates the trigger expansion temperature T of the thermal expansion microcapsules within the thermal expansion protection layer to 70°C to 80°C (higher than the battery's maximum operating temperature to avoid non-fault false triggering). Utilizing the endothermic phase change characteristics of the thermal expansion microcapsules when they expand under heat, it can quickly achieve heat absorption and temperature control and physical insulation when the battery abnormally heats up. This provides reliable intrinsic safety protection for flexible heated wearable scenarios that are close to the body, allowing the battery to have targeted thermal runaway protection capabilities while possessing wearability characteristics such as ultra-thinness, flexibility, and bend resistance, significantly improving its safety in clothing applications.

[0016] Preferably, the thermal expansion protective layer is bonded to the flexible battery body by hot melt adhesive, and the area coverage of the flexible battery body is >95%.

[0017] Specifically, the hot melt adhesive bonding method achieves a firm and integrated bond between the thermal expansion protective layer and the battery body without compromising the overall flexibility of the battery. This ensures that the thermal expansion protective layer does not fall off or shift during the dynamic bending and deformation of the battery with the wearable device. The ultra-high area coverage of >95% eliminates blind spots on the battery surface, ensuring that the thermal expansion protective layer can respond quickly and function when any area of ​​the battery experiences abnormal temperature rise, blocking heat spread in all directions and maximizing the safety protection effect in close-fitting wear scenarios.

[0018] Preferably, the thickness of the thermal expansion protective layer increases to more than 300% of its original thickness after expansion, and the thermal conductivity after expansion is less than 0.1 W / (m). K).

[0019] Specifically, an expansion thickness of over 300% can quickly form a physical heat insulation layer, effectively preventing abnormal heat from the battery from spreading to the surrounding area; less than 0.1W / (m²) The ultra-low thermal conductivity of K significantly reduces heat transfer efficiency from the perspective of thermal conductivity performance. The two work together to achieve a dual high-efficiency blockage of heat spread, which can accurately and quickly isolate abnormal heat sources of the battery from the close-fitting textiles, maximize the safety and heat insulation effect of the protective layer, and meet the core safety protection needs of close-fitting wear.

[0020] Accordingly, the present invention also provides an intelligent heating system, including the ultra-thin flexible safety battery, the flexible planar heating element and the intelligent temperature controller as described above. The ultra-thin flexible safety battery and the flexible planar heating element are connected in series with the intelligent temperature controller to form a closed loop for supplying power to the flexible planar heating element. The intelligent temperature controller can adjust the heating power of the flexible planar heating element and monitor the electrical parameters and temperature parameters of the ultra-thin flexible safety battery. Specifically, when the temperature of the ultra-thin flexible safety battery exceeds the first warning threshold but is lower than the trigger expansion temperature T, the intelligent temperature controller will reduce the heating power of the flexible planar heating element or cut off the power supply; the first warning threshold is 60℃~65℃.

[0021] Specifically, this intelligent heating system employs a closed-loop design combining an ultra-thin, flexible, safe battery, a flexible planar heating element, and an intelligent temperature controller. This design leverages the flexibility of each component to adapt to the dynamic usage requirements of wearable scenarios, while the intelligent temperature controller enables flexible adjustment of heating power to meet personalized thermal management needs. Simultaneously, the intelligent temperature controller monitors battery electrical parameters and temperature in real time. When the temperature falls below the first warning threshold of 60℃~65℃ (below the trigger expansion temperature), it promptly performs power reduction or power-off operations, forming targeted proactive safety protection. This effectively mitigates the risks associated with excessively high battery temperatures, allowing the system to significantly improve operational safety and reliability while maintaining stable heating functionality and wearability. This provides an efficient and safe heating solution for flexible heated wearable products.

[0022] Preferably, the flexible planar heating element is one of a carbon nanotube film, a graphene film, or a carbon nanotube-graphene composite film, with a surface resistivity of 5–10 Ω / m. 2 .

[0023] Specifically, the selection of carbon nanotube films, graphene films, or their composite films combines excellent flexibility and uniform planar heating characteristics, allowing them to dynamically bend with wearable devices and provide uniform, close-fitting heating, thus adapting to the application scenarios of flexible wearables; 5~10Ω / m 2The surface resistance range is precisely matched to the power supply characteristics of the ultra-thin flexible safety battery, which not only ensures that the heating element outputs heating power that meets the individual thermal management needs, but also avoids problems such as insufficient heating or excessive power consumption caused by resistance imbalance. It balances heating effect and power supply life, and realizes system-level performance synergy between heating unit and power supply core.

[0024] Accordingly, the present invention also provides a wearable product, including the above-mentioned intelligent heating system and wearable fabric, wherein the flexible planar heating element of the intelligent heating system is integrated into the wearable fabric by sewing.

[0025] Specifically, this wearable device combines a highly adaptable intelligent heating system with wearable fabric using a sewing integration process. This not only meets the industrial production needs of the textile industry but also ensures a firm bond between the flexible, planar heating element and the wearable fabric. This guarantees that the heating element will not detach or shift during dynamic bending and crunching of the wearable device, ensuring the stability of the heating function. Furthermore, leveraging the ultra-thin and flexible nature of the intelligent heating system itself, the integration does not disrupt the normal wearing experience of the device, resulting in no noticeable foreign body sensation. The system's built-in tiered safety protection system and integrated thermal expansion protection design of the battery fundamentally ensure the safety of close-fitting use. This allows the wearable device to combine a comfortable wearing experience, precise and stable personal thermal management heating function, and a high level of safety, perfectly adapting to the actual application scenarios of various wearable products such as clothing and footwear.

[0026] Preferably, the wearable fabric includes a base layer and a second waterproof coating layer laminated therein, with the ultra-thin flexible safety battery integrated inside the wearable fabric and fully covered by the second waterproof coating layer; the material of the second waterproof coating layer is selected from ePTFE, TPU or PU.

[0027] Specifically, this wearable fabric employs a composite design of a base layer and a second waterproof coating layer that fully covers the ultra-thin flexible safety battery. This design leverages the excellent waterproofness and flexibility of ePTFE, TPU, or PU materials to comprehensively prevent moisture intrusion, protecting the ultra-thin flexible safety battery and preventing it from being affected by moisture, thus avoiding potential safety hazards or impacting its heating performance. Simultaneously, it allows the ultra-thin flexible safety battery to be securely integrated within the fabric without compromising its normal feel and flexibility. The overall design is suitable for both daily use and dynamic activities, while further enhancing the waterproof protection of the intelligent heating system, significantly improving the safety, structural stability, and wearing comfort of heated wearable products.

[0028] The beneficial effects of this invention are as follows: Unlike existing technologies, this invention provides an ultra-thin flexible safety battery, an intelligent heating system, and wearable devices. The ultra-thin flexible safety battery possesses an extremely thin structure, along with a high waterproof rating and high stability after tens of thousands of bends. Its precise performance parameter design perfectly matches the wearable device's requirement for an imperceptible thickness of the power supply unit, adapts to the dynamic bending scenarios of clothing, and can withstand the complex environments of daily wear such as sweat and washing. It solves the technical problems of insufficient flexibility and poor waterproofing of traditional power supply components, making them unsuitable for the needs of wearable devices, from the core power supply end. The intelligent heating system built based on this core battery, relying on the battery's excellent flexibility and waterproofing, can be used in wearable applications. The system is highly adaptable to various scenarios, achieving system-level coordination of power supply, heating, and temperature control. It can adjust the heating power as needed to meet individual thermal management requirements, and the structural and performance stability of the battery itself greatly improves the system's operational reliability in dynamic wearable scenarios. Wearable products integrating this intelligent heating system achieve a firm bond between the heating element and the fabric through a sewing integration process. Relying on the ultra-thin and highly flexible characteristics of the core battery, it completely eliminates the foreign body sensation caused by the power supply unit, retaining the normal wearing comfort. It not only meets the industrial production requirements of the textile industry, but also, thanks to the waterproof and flexible nature of the battery, allows the end product to have both a comfortable wearing experience and stable heating function in daily wear and dynamic activities, greatly improving the performance and scenario adaptability of wearable products. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the dedicated ultra-thin flexible safety battery provided by the present invention; Figure 2A A physical image of the flexible battery body in a non-bent state in the special ultra-thin flexible safety battery provided by the present invention; Figure 2B A photograph of the flexible battery body in a bent state in the special ultra-thin flexible safety battery provided by the present invention; Figure 3 Comparison of the structure of the thermal expansion protection layer in the special ultra-thin flexible safety battery provided by the present invention under normal and triggered expansion states; Figure 4 Circuit connection diagram of the intelligent heating system provided by the present invention; In the attached diagram: 100—ultra-thin flexible safety battery; 10—flexible battery body; 20—thermal expansion protective layer; 200—flexible planar heating element; 21—thermal expansion microcapsule; 300—intelligent temperature controller. Detailed Implementation

[0030] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0031] To address the aforementioned deficiencies or improvement needs of existing technologies, this invention, starting from the ultimate application constraints of flexible heated clothing requiring tens of thousands of bends, millimeter-thin thickness, and absolute fire resistance, defines and designs an inseparable dedicated power supply core unit. Its primary objective is to provide an ultra-thin, flexible, and safe battery specifically for flexible heated wearables. This battery is not a simple optimization of existing flexible batteries, but rather, based on the minimum necessary conditions for clothing integration, it integrates an ultra-thin, fatigue-resistant structure with an integrated physical safety mechanism, ensuring that all its characteristic parameters meet the aforementioned necessary and sufficient conditions for clothing application. Furthermore, another objective of this invention is to provide an intelligent heating system incorporating this dedicated battery. This system, through deep coupling of the dedicated battery, flexible heating element, and intelligent controller, constructs a closed-loop management system optimized for flexible dynamic substrates and possessing a dual safety mechanism of "active warning - passive fuse".

[0032] Please see Figures 1 to 3 The present invention first provides an ultra-thin flexible safety battery 100, including a flexible battery body 10, the thickness of the flexible battery body 10 being 0.1-0.5mm, and the waterproof rating being IPX7. Among them, the flexible battery body 10, after being repeatedly bent 10,000 times with a bending radius of 5mm and a bending angle of 120°, has a capacity retention rate of ≥90% and an internal resistance increase of ≤20%; after multiple flexible battery bodies undergo 30 cycles of 180° folding and compaction, the physical damage rate by quantity is ≤0.1%.

[0033] Specifically, the flexible battery body 10 includes a cell unit group, an encapsulation layer, and a first waterproof coating layer; the encapsulation layer completely wraps around and adheres to the outer surface of the cell unit group, and the first waterproof coating layer completely wraps around and adheres to the outer surface of the encapsulation layer. The battery cell unit group includes multiple battery cell units arranged side by side and connected in series. The battery cell unit is a polymer gel lithium-ion battery cell or a solid lithium-ion battery cell. The encapsulation layer is a flexible aluminum-plastic film. The material of the first waterproof coating layer is selected from one of ePTFE material, TPU material or PU material.

[0034] In this embodiment of the invention, the ultra-thin flexible safety battery 100 is a functional unit customized for wearable applications. Its structure follows the design principle of "form follows function," with the core being the flexible battery body 10, such as... Figure 2A and Figure 2BAs shown; the flexible battery body 10 is used to specifically address the constraints of wearability and durability in wearable applications, and its specific design specifications and performance requirements are as follows: Thickness: The flexible battery body 10 adopts a thickness of 0.1 to 0.5 mm, which is the "imperceptible thickness" threshold determined by simulation and wearing experiments. If it is less than 0.1 mm, it is difficult to guarantee the necessary energy density and packaging reliability of the battery. If it is greater than 0.5 mm, it will produce obvious foreign body sensation at the joints of clothing and affect the wearing comfort.

[0035] Flexible durability: The flexible battery body 10 adopts a cell unit group fully wrapped in flexible aluminum-plastic film. The cell unit group is composed of multiple polymer gel lithium-ion cells or solid lithium-ion cells connected in parallel. The cell materials and stacking process are all fatigue-resistant and specially designed, and must pass rigorous performance verification: after repeated bending 10,000 times at a bending radius of 5mm and a bending angle of 120°, the capacity retention rate is ≥90% and the internal resistance increase is ≤20%; it can withstand 30 compaction cycles in a 180° fully folded state, and the physical damage rate by quantity is ≤0.1%, with no problems such as encapsulation cracking or tab breakage. This performance can ensure that the battery has the same lifespan as the wearable fabric.

[0036] Waterproof rating: The overall structure of the flexible battery body 10 reaches IPX7 level, which can cope with daily wear, washing and other usage scenarios.

[0037] In this embodiment of the invention, the ultra-thin flexible safety battery 100 further includes a thermal expansion protection layer 20 integrally formed with the flexible battery body 10, and the thermal expansion protection layer 20 is disposed on at least one outer surface of the flexible battery body 10 with the largest area. The thermal expansion protective layer 20 includes a substrate and thermal expansion microcapsules uniformly dispersed in the substrate; the thermal expansion microcapsules expand when heated and undergo an endothermic phase change, and their trigger expansion temperature T is 70℃~80℃, which is greater than the maximum operating temperature of the flexible battery body.

[0038] Specifically, the thermal expansion protective layer 20 is used to achieve intrinsic safety protection in close-fitting applications of flexible heated wearables, adapting to the structural characteristics and usage requirements of the flexible battery body 10. The specific design and working principle are as follows: The thermal expansion protection layer 20 is a prefabricated functional thin film structure, which is bonded to at least one of the largest outer surfaces of the flexible battery body 10 by hot melt adhesive, and the area coverage of the thermal expansion protection layer 20 on the flexible battery body 10 is >95%. The above-mentioned integrated bonding design can ensure that the thermal expansion protection layer 20 and the flexible battery body 10 have no relative displacement as they deform, thus ensuring the reliability of the protection response.

[0039] Please see Figure 3Thermal expansion microcapsules 21 are uniformly dispersed in the matrix of the thermal expansion protective layer 20. The trigger expansion temperature of the thermal expansion microcapsules 21 is precisely calibrated to 70℃~80℃, preferably 72±2℃. This trigger expansion temperature T is higher than the maximum operating temperature of the flexible battery body 10 and much lower than the ignition point of common textiles. When the flexible battery body 10 abnormally heats up to the trigger expansion temperature due to internal fault, the thermal expansion microcapsules 21 expand instantly, causing the thermal expansion protective layer 20 to expand as a whole, and its thickness increases to more than 300% of the original thickness.

[0040] The expansion process of the thermally expandable microcapsule 21 is accompanied by a strong endothermic phase transition, which can quickly absorb the heat energy generated by the abnormal temperature rise of the flexible battery body 10, thus achieving rapid temperature control; at the same time, the porous carbonized layer formed after the thermal expansion protective layer 20 expands has a thermal conductivity of less than 0.05 W / (m²). K) can construct a physical thermal insulation barrier between the flexible battery body 10 and the wearable fabric, fundamentally blocking the propagation path of thermal runaway and achieving inherent safety protection in close-fitting application scenarios.

[0041] In this embodiment of the invention, the ultra-thin and flexible characteristics of the flexible battery body 10 and the integrated design of the thermal expansion protection layer 20 form a synergistic and compatible relationship. On the one hand, the ultra-thin structure of the flexible battery body 10 provides a flat and stable substrate for the thermal expansion protection layer 20, effectively ensuring the strong adhesion between the two and the uniformity of the trigger response of the thermal expansion protection layer 20. On the other hand, the integrated design of the thermal expansion protection layer 20 allows the battery to still possess inherent safety protection capabilities against extreme risks such as thermal runaway, even with an ultra-thin packaging structure. The two form a complementary and interdependent integrated design, neither of which can be omitted, jointly ensuring the adaptability and safety of the battery in flexible heated clothing scenarios.

[0042] Please see Figure 4 The present invention also provides an intelligent heating system, which includes the aforementioned ultra-thin flexible safety battery 100, flexible planar heating element 200, and intelligent temperature controller 300; wherein the ultra-thin flexible safety battery 100 and the flexible planar heating element 200 are both connected in series with the intelligent temperature controller 300, forming a closed functional loop for supplying power to the flexible planar heating element 200. Through the deep coupling design of its components, this system achieves precise temperature control and intrinsic safety protection for flexible heated clothing. Specific technical features are as follows: Flexible planar heating element 200: preferably with a surface resistivity of 5-10 Ω / m 2 One of the following—a carbon nanotube film, a graphene film, or a carbon nanotube-graphene composite film—is integrated into wearable fabric via a sewing process. Its sheet resistivity parameters are precisely matched with the output voltage (e.g., 5V–7.4V) of the ultrathin flexible safety battery 100, enabling efficient conversion of electrical energy into heat energy and meeting the heating needs of flexible heated clothing.

[0043] Intelligent temperature controller 300: Connected in series in the main power supply circuit of the system, as the core control unit of the system, it has two core functions: First, it performs comfortable temperature control operation based on user commands or sensor feedback signals, and can adjust the heating power of the flexible surface heating element 200; Second, it monitors the electrical parameters (output current, voltage) and temperature parameters (battery surface or near-end temperature) of the ultra-thin flexible safety battery 100 in real time with high precision.

[0044] Collaborative Safety Mechanism (Dual Protection Mechanism): The intelligent heating system, through the collaborative design of active electronic protection and passive physical protection, is deeply coupled with the physical characteristics of the ultra-thin flexible safety battery 100, forming a complete safety solution for flexible heated clothing, specifically including two layers of protection: (1) Active electronic early warning protection (executed by intelligent temperature controller 300): When the intelligent temperature controller 300 detects that the ultra-thin flexible safety battery 100 has an abnormal current or its temperature exceeds the first warning threshold (60℃~65℃) and is lower than the trigger expansion temperature T of the thermal expansion protection layer 20, it immediately performs the operation of reducing the heating power of the flexible planar heating element 200 or cutting off the power supply circuit to contain the safety risk in the bud.

[0045] (2) Second layer: Passive physical isolation protection (executed by thermal expansion protection layer 20): If the temperature of the ultra-thin flexible safety battery 100 continues to rise to the trigger expansion temperature T due to extreme scenarios (such as failure of active electronic warning or external fire source), the thermal expansion protection layer 20 will automatically trigger thermal expansion action. Through the strong heat absorption phase change and the low thermal conductivity of the porous carbonized layer, a physical isolation barrier is constructed between the battery and the clothing fabric to achieve the ultimate intrinsic safety protection that does not rely on the circuit.

[0046] The present invention also provides a wearable product, including the above-mentioned intelligent heating system and wearable fabric, wherein the flexible planar heating element 200 of the intelligent heating system is integrated into the wearable fabric by sewing.

[0047] Furthermore, the wearable fabric includes a base layer and a second waterproof coating layer laminated therein. The ultra-thin flexible safety battery is integrated inside the wearable fabric and is fully covered by the second waterproof coating layer. The material of the second waterproof coating layer is selected from one of ePTFE, TPU or PU materials.

[0048] The technical solution of the present invention will be further described in detail below with reference to specific embodiments. It should be understood that the following embodiments are merely illustrative and explanatory of the present invention and should not be construed as limiting the scope of protection of the present invention. All technologies implemented based on the above content of the present invention are covered within the scope of protection intended by the present invention. Unless otherwise stated, the raw materials used in the following embodiments are commercially available products or can be prepared by known methods.

[0049] Example 1: Example 1 first provides an ultra-thin flexible safety battery 100, including a flexible battery body 10 and a thermal expansion protection layer 20 integrally formed with the flexible battery body 10. The thermal expansion protection layer 20 is disposed on at least one outer surface of the flexible battery body 10 with the largest area. The thermal expansion protective layer 20 includes a substrate and thermal expansion microcapsules 21 uniformly dispersed in the substrate; the thermal expansion microcapsules 21 expand when heated and undergo an endothermic phase change, and their expansion trigger temperature T is 70℃~80℃, which is greater than the maximum operating temperature of the battery body.

[0050] In Example 1, the fabrication process of the flexible battery body 10 is as follows: a commercially available stacked polymer gel lithium-ion cell with an initial thickness of 0.22 mm is selected; the cell is vacuum heat-sealed using a 38 μm thick nylon layer / aluminum foil / polypropylene composite film (i.e., aluminum-plastic film). The sealing process parameters are set as follows: heat sealing temperature 165℃, pressure 0.4 MPa, and time 4 s. After sealing, the overall thickness of the battery cell is 0.32 mm; the nominal capacity of the flexible battery cell is 850 mAh, and the internal resistance is ≤80 mΩ.

[0051] In Example 1, the integration process of the thermal expansion protective layer 20 and the flexible battery body 10 is as follows: A commercially available thin thermal expansion fire-retardant film is selected as the thermal expansion protective layer 20. The substrate of the thermal expansion protective layer 20 is polyimide, containing acrylonitrile-based thermal expansion microcapsules 21. It is cut to a suitable size and covered on one main plane of the product obtained in the aforementioned flexible battery body 10 preparation steps, with an area coverage rate > 95%. The two are pressed together using a flatbed hot press, with the pressing process parameters being: temperature 110°C, pressure 0.2 MPa, and time 30 s. After pressing, the thermal expansion protective layer 20 and the flexible battery body 10 are firmly bonded together, and the overall thickness of the finally obtained ultra-thin flexible safety battery 100 is increased by approximately 0.12 mm compared to the original flexible battery body 10.

[0052] The performance tests and effect verifications of the ultrathin flexible safety battery 100 provided in Example 1 are as follows: Flexibility and durability testing: The prepared sample batteries underwent flexibility and durability testing under conditions simulating actual clothing bending scenarios: bending radius R = 5mm, bending angle 180°, and frequency 40 cycles / minute. After 10,000 bending cycles, the sample remained intact with no encapsulation cracking; electrical performance testing results showed a capacity retention rate of 93.5% and an internal resistance increase rate of 18%.

[0053] Safety protection performance test: A controllable temperature hot plate was used to locally heat the non-protected surface of the battery sample, and thermocouples and thermal imagers were used to monitor the surface temperature and morphology changes of the thermal expansion protective layer 20. When the thermal imager showed that the temperature of the protective layer area rose to 73°C, a significant bulge appeared in the area within about 2 seconds; after cooling, the thickness at the center of the expanded area was measured to be 3.8 times the initial thickness.

[0054] Thermal insulation control experiment: The battery area with the thermal expansion protective layer 20 was continuously heated, and the heat flux density on its back side was measured using a heat flux sensor. Test data showed that after the thermal expansion protective layer 20 was triggered to expand, the heat flux density on its back side decreased by approximately 85%, confirming its significant thermal insulation effect.

[0055] Accordingly, this embodiment 1 also provides an intelligent heating system, which includes the aforementioned ultra-thin flexible safety battery 100, flexible planar heating element 200, and intelligent temperature controller 300. The ultra-thin flexible safety battery 100 and the flexible planar heating element 200 are both connected in series with the intelligent temperature controller 300, forming a closed functional loop that supplies power to the flexible planar heating element 200. Through the deep coupling design of each component, this system achieves precise temperature control and intrinsic safety protection for the flexible heated clothing. System integration testing was conducted, and the testing process and results are as follows: The aforementioned ultrathin flexible safety battery 100 has a surface resistivity of 7.5Ω / m. 2 The system is connected to a carbon nanotube heating film and integrated with a PID intelligent temperature controller 300 (Proportional-Integral-Derivative Intelligent Temperature Controller) with temperature feedback function. The operating temperature of the intelligent heating system is set to 45℃. Test results show that the intelligent heating system can operate stably and accurately maintain the set operating temperature. An external heat source is used to heat the battery to simulate abnormal temperature rise. When the temperature controller detects that the battery temperature has risen to 65℃, it immediately issues an alarm signal and cuts off the main power supply circuit; after the external heat source is removed, the system can return to normal operation. During extreme testing, the battery is continuously heated until its temperature rapidly exceeds 70℃. It can be observed that the battery's thermal expansion protection layer 20 triggers the expansion action as designed, successfully achieving physical safety protection.

[0056] This invention discloses an ultra-thin flexible safety battery 100, an intelligent heating system, and wearable devices. The ultra-thin flexible safety battery 100, designed using a reverse engineering approach, adapts to the extreme application constraints of flexible heated wearable devices. Its core is an integrated, indivisible structure that tightly combines a flexible battery body 10 (0.1–0.5 mm thick, resistant to tens of thousands of bends) with a thermal expansion protective layer 20, integrated with the flexible battery body 10 via hot melt adhesive and capable of expanding at 70–80°C. This clearly defines the core necessary conditions for the application of flexible batteries in this field. Simultaneously, the intelligent heating system, incorporating the ultra-thin flexible safety battery 100, further integrates an intelligent temperature controller 300 to form a dual safety mechanism of "active warning - passive meltdown," achieving inherent safety protection in close-fitting application scenarios. Through specific embodiments and detailed test data, this invention fully verifies the core technical effects of the battery and heating system, including their ultra-thin flexibility, bend resistance, durability, and safety protection, providing a standardized, high-tech, and indispensable core power supply solution for the field of flexible heated wearable devices.

[0057] In summary, compared with the prior art, the technical solution provided by this invention has the following characteristics: (1) Establishing exclusive technical access standards for the field of heated clothing: This invention clarifies for the first time that the ultra-thin flexible safety battery applied to heated wearables must simultaneously meet three core characteristics at the single-cell level: ultra-thin thickness of 0.1 to 0.5 mm, durability of 10,000 bends, and integrated physical protection triggered by 70 to 80°C. This sets clear and high-barrier technical access requirements for the industry.

[0058] (2) Achieving ultimate safety protection in close-fitting application scenarios: The dual safety mechanism of active electronic warning and passive physical protection designed in this invention effectively fills the protection gap when the electronic system fails completely. Among them, passive physical protection serves as the last line of defense, effectively realizing the inherent safety of heated wearable products in close-fitting application scenarios.

[0059] (3) Ensuring the ultimate clothing wearing experience: The ultra-thin and ultra-soft characteristics of the special battery of this invention allow it to be cut and sewn like ordinary clothing lining, completely eliminating the discomfort of wearing such as bulkiness and stiffness caused by traditional power supply solutions, and realizing the deep integration of heating technology and clothing products.

[0060] (4) Constructing system-level operational reliability across the entire chain: From dedicated batteries and flexible planar heating elements 200 to intelligent temperature controllers 300, all core components are customized and selected around the common application constraint of "flexible dynamic substrate" of flexible heated clothing, ensuring that the system maintains overall operational stability and reliability in actual wearing scenarios with long-term complex deformation.

[0061] (5) The key technical effects have clear verifiability and reproducibility: Through the design of specific embodiments and detailed test data, this invention fully proves that the claimed key technical effects such as ultra-thin flexibility, bending resistance and long life, rapid thermal expansion triggering and high-efficiency heat insulation are all specific, achievable and reproducible, which greatly improves the credibility and application prospects of the technical solution.

[0062] It should be noted that all the above embodiments belong to the same inventive concept, and the descriptions of each embodiment have different focuses. Where the description in a particular embodiment is not detailed, please refer to the description in other embodiments.

[0063] The above embodiments merely illustrate implementation methods of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. An ultra-thin flexible safety battery, characterized in that, It includes a flexible battery body, the thickness of which is 0.1 to 0.5 mm; The flexible battery body, after being repeatedly bent 10,000 times with a bending radius of 5mm and a bending angle of 120°, retains a capacity of ≥90% and an internal resistance increase of ≤20%.

2. The ultra-thin flexible safety battery according to claim 1, characterized in that, The flexible battery body has an IPX7 waterproof rating; after multiple flexible battery bodies undergo 30 cycles of 180° folding and compaction, the physical damage rate by quantity is ≤0.1%.

3. The ultra-thin flexible safety battery according to claim 2, characterized in that, The flexible battery body includes a cell unit group, an encapsulation layer, and a first waterproof coating layer; the encapsulation layer completely wraps around and adheres to the outer surface of the cell unit group, and the first waterproof coating layer completely wraps around and adheres to the outer surface of the encapsulation layer. The battery cell unit group includes multiple battery cell units arranged side by side and connected in series. The battery cell unit is a polymer gel lithium-ion battery cell or a solid lithium-ion battery cell. The encapsulation layer is a flexible aluminum-plastic film. The material of the first waterproof coating layer is selected from ePTFE material, TPU material or PU material.

4. The ultra-thin flexible safety battery according to claim 1, characterized in that, The ultra-thin flexible safety battery also includes a thermal expansion protection layer integrally formed with the flexible battery body, and the thermal expansion protection layer is disposed on at least one outer surface of the flexible battery body with the largest area. The thermal expansion protective layer includes a substrate and thermal expansion microcapsules uniformly dispersed in the substrate; the thermal expansion microcapsules expand when heated and undergo an endothermic phase change, and their expansion trigger temperature T is 70℃~80℃, which is greater than the maximum operating temperature of the flexible battery body.

5. The ultra-thin flexible safety battery according to claim 4, characterized in that, The thermal expansion protective layer is bonded to the flexible battery body with hot melt adhesive, and its area coverage on the flexible battery body is >95%.

6. The ultra-thin flexible safety battery according to claim 5, characterized in that, The thermal expansion protective layer expands to a thickness of more than 300% of its original thickness, and its thermal conductivity after expansion is less than 0.1 W / (m²). K).

7. An intelligent heating system, characterized in that, The device includes an ultra-thin flexible safety battery, a flexible planar heating element, and an intelligent temperature controller as described in any one of claims 1 to 6, wherein the ultra-thin flexible safety battery and the flexible planar heating element are connected in series with the intelligent temperature controller to form a closed loop for supplying power to the flexible planar heating element; the intelligent temperature controller can adjust the heating power of the flexible planar heating element and monitor the electrical and temperature parameters of the ultra-thin flexible safety battery. When the temperature of the ultra-thin flexible safety battery exceeds the first warning threshold but is lower than the trigger expansion temperature T, the intelligent temperature controller performs operations to reduce the heating power of the flexible planar heating element or cut off the power supply; the first warning threshold is 60℃~65℃.

8. The intelligent heating system according to claim 7, characterized in that, The flexible planar heating element is one of a carbon nanotube film, a graphene film, or a carbon nanotube-graphene composite film, with a surface resistivity of 5–10 Ω / m. 2 .

9. A wearable product, characterized in that, Includes the intelligent heating system and wearable fabric as described in any one of claims 7 to 8, wherein the flexible planar heating element of the intelligent heating system is integrated into the wearable fabric by sewing.

10. The wearable article according to claim 9, characterized in that, The wearable fabric includes a base layer and a second waterproof coating layer laminated therein. The ultra-thin flexible safety battery is integrated inside the wearable fabric and is fully covered by the second waterproof coating layer. The material of the second waterproof coating layer is selected from ePTFE, TPU or PU.

Images