3D Shaped Battery With Stacked Pattern Units
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Solution Overview
Problem
Conventional batteries are typically rectangular in shape, making it difficult to efficiently utilize limited space in portable electronic devices with varied designs, leading to increased demand for batteries that can be flexibly mounted in non-standard shapes.
Innovation Solution
Three-dimensional shaped batteries with a cell structure comprising pattern units of varying sizes and connecting portions that can be bent or folded, allowing for a customized fit within the internal shape of electronic devices, along with a method of manufacturing involving electrode active material layers coated on current collectors using printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rectangular batteries are used, then manufacturing and assembly are simple, but space utilization in portable electronic devices is poor
Solution Approach 1:
The battery is divided into multiple pattern units (first pattern unit, second pattern unit, etc.) with different areas that can be arranged in a stacked configuration. This segmentation allows the battery to adapt to irregular internal spaces in electronic devices while maintaining manufacturability through modular assembly of standardized components.
Solution Approach 2:
The patent transitions from a conventional two-dimensional rectangular battery layout to a three-dimensional stacked structure with pattern units arranged in multiple layers. This dimensional change enables better space utilization by utilizing vertical stacking and irregular area patterns rather than simple rectangular footprints.
2Volume of moving object
If battery shape is customized to match device internal shape, then space utilization improves, but device complexity increases
Solution Approach 1:
The battery structure is segmented into multiple pattern units with different areas that can be stacked to match the device's internal shape. This segmentation allows customization of the overall battery form factor while maintaining relatively simple individual unit structures, thereby reducing overall manufacturing complexity.
Solution Approach 2:
The pattern units are designed with universal characteristics that allow them to be stacked in different configurations to match various device internal shapes. The connecting portions and electrode structures follow standardized designs that can be adapted to different device requirements, reducing the need for completely custom designs for each application.
3Adaptability or versatility
If pattern units are stacked to form three-dimensional structure, then adaptability to device shapes improves, but manufacturing precision requirements increase
Solution Approach 1:
The battery is divided into discrete pattern units that can be manufactured separately and then stacked. This segmentation allows for standardized manufacturing of individual units with controlled tolerances, reducing the cumulative precision requirements compared to manufacturing a single complex three-dimensional structure.
Solution Approach 2:
Different pattern units have different areas optimized for specific positions in the stack (e.g., intermediate portions with greater or less area). This local optimization allows each unit to be manufactured with precision requirements tailored to its specific function and position, rather than requiring uniform high precision across the entire structure.
Data Source
AI summary
A three-dimensional shaped battery includes a cell structure including a first electrode layer, a second electrode layer, and a separation layer disposed between the first electrode layer and the second electrode layer, where the cell structure may include a plurality of pattern units having different sizes from each other and a connecting portion which connects the pattern units to each other.