Battery Cell Integrated into Device Cavity
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Solution Overview
Problem
Conventional batteries in electronic devices, such as pens, occupy space and limit ink capacity due to their shape, resulting in sub-optimal use of space and reduced battery run-time.
Innovation Solution
Integrating a battery cell into the electronic device by utilizing cavities within the device, with a metal outer housing acting as a current collector and a conductive foam or metal foam as an anode, allowing for efficient use of space and improved energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard shaped batteries are placed into the device, then the device can be manufactured using conventional methods, but the space utilization is sub-optimal and battery run-time is limited
Solution Approach 1:
The battery is nested within an existing cavity in the device housing, utilizing the available space efficiently. The battery fits inside the cavity that was originally designed for other components, thereby maximizing space utilization without requiring additional manufacturing steps for the housing structure.
Solution Approach 2:
The battery is designed with a custom three-dimensional shape that conforms to the cavity geometry, transitioning from standard cylindrical or button cell forms to a molded configuration that exploits the full volumetric capacity of the available space in multiple dimensions.
2Adaptability or versatility
If standard shaped batteries are placed into the device, then conventional battery components can be used, but the space for ink is reduced and ink capacity is limited
Solution Approach 1:
The device is segmented into distinct functional zones: the battery occupies the cavity space, while the ink tube and refill mechanisms are positioned in separate regions. This segmentation allows the ink tube to extend fully without being blocked by the battery, maintaining adequate ink capacity.
Solution Approach 2:
The battery is nested within the device cavity in a position that does not interfere with the ink tube pathway. The ink tube is routed around or over the battery placement area, allowing both components to coexist in the limited space without compromising ink capacity.
3Ease of operation
If coin-cell batteries are used to provide power, then the device can operate with standard electrical components, but the packaging overhead is high and energy storage is low
Solution Approach 1:
The battery parameters are changed from standard coin-cell dimensions to a custom molded shape with increased volume. The battery uses a liquid electrolyte system with higher energy density compared to solid-state coin cells, thereby storing more energy in the available space while maintaining electrical compatibility with existing components.
Solution Approach 2:
The battery employs composite construction with a molded housing, liquid electrolyte, and custom-shaped electrodes. This composite approach allows optimization of energy density while fitting the specific geometric constraints of the device cavity, achieving superior energy storage compared to conventional coin-cell designs.
Data Source
AI summary
An electronic device, including a housing that is metal or lined with an electrically conductive material, at least one electrical component, and a battery cell positioned in a cavity in the outer housing, the battery cell integrated into the electronic device. The battery cell includes a first current collector and an active cell core. The first current collector is the electrically conductive material of the outer housing of the electronic device and connects to the at least one electrical component. The active cell core includes a first active material in adjacent facing relation to and electrically coupled to the first current collector, a second active material; a separator positioned between the first active material and the second active material; and a second current collector electrically coupled with the second active material, wherein the second current collector connects to the at least one electrical component.