Articulate Battery Case Segmented Hinge Design
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Solution Overview
Problem
Existing battery cases lack conformal flexibility and articulation, making them unsuitable for housing multiple non-flexible battery modules while maintaining electrical interconnectivity and conforming to user shapes.
Innovation Solution
An articulate battery case with multiple rigid compartments connected by flexible hinges, allowing for articulation and electrical interconnectivity between non-contiguous battery segments, using various types of hinges such as living, coiled spring, wavy, and compressible hinges, and reversible or irreversible fasteners to form linear, matrix, or circular arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible battery case is used to maintain conformal flexibility, then the battery case can conform to user shapes, but it cannot house multiple non-flexible battery modules effectively
Solution Approach 1:
The battery case is divided into multiple rigid compartments that can be separately manufactured to house non-flexible battery modules. Each compartment is a discrete unit that can be precisely engineered for its specific battery module, while the overall segmented structure provides the necessary flexibility through articulated connections.
Solution Approach 2:
The battery case transitions from a static flexible structure to a dynamic articulated structure. The rigid compartments are connected via flexible hinges that allow the case to adapt its shape dynamically while maintaining structural integrity and proper housing for non-flexible battery modules within each compartment.
2Ease of manufacture
If rigid compartments are used to house non-flexible battery modules, then the housing capability is improved, but the conformal flexibility is lost
Solution Approach 1:
The introduction of flexible hinges between rigid compartments transforms the overall structure from static to dynamic. While individual compartments remain rigid to properly house non-flexible battery modules, the articulated connections enable the entire battery case to flex and conform to various shapes and movements.
Solution Approach 2:
The flexible hinges act as flexible connections between rigid compartments. These hinge elements provide the necessary flexibility and conformability while allowing the rigid compartments to maintain their structural integrity for housing non-flexible battery modules effectively.
3Productivity
If multiple non-contiguous battery segments are electrically interconnected, then the battery ensemble functionality is improved, but the structural complexity increases
Solution Approach 1:
The battery system is segmented into multiple independent battery modules, each housed in its own compartment. This segmentation allows each module to be independently managed and connected through conductive leads that pass through aligned ports, simplifying the overall interconnection architecture while maintaining functional versatility.
Solution Approach 2:
The articulated battery case design provides a universal platform that can accommodate various configurations of battery modules. The standardized compartment design with aligned ports enables flexible electrical interconnections for different battery ensemble functionalities without requiring complex custom wiring arrangements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The articulate battery case enables flexible and conformable housing of multiple battery segments, maintaining electrical connectivity and allowing the battery ensemble to conform to user shapes, enhancing usability and transportability.
Implementation Method 1
Preferred hinges are resilient, e.g., living hinges. Alternative embodiments of this aspect of the invention may employ linear hinges, coiled spring hinges, wavy hinges, zagged hinges, and diagonally attached hinges. Alternatively, the hinge may have an elastic composite composition.
Data Source
AI summary
An articulate battery case encases a battery ensemble having multiple non-contiguous battery segments flexibly interconnected to one another by conductive leads. The articulate battery case employs a plurality of rigid compartments for encasing the battery ensemble. Each compartment is configured for encasing one non-contiguous battery segment. Each compartment is flexibly connected by one or more flexible hinge to at least one adjoining compartment and is articulate therewith. Each compartment defines one or more ports for interconnecting conductive leads between battery segments encased in adjoining compartments. Each compartment is interconnected to every other compartment, with or without one or more intervening compartment. When a battery ensemble is encased within the articulate battery case, it is rendered articulate, i.e., it acquires the articulation characteristics of the case within which it is contained.