3D Battery Cell with Shape-Conforming Conductive Covering
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Solution Overview
Problem
Traditional battery cells face limitations in current delivery due to long conduction paths and electronic traffic jams, leading to slow charge times and reduced power output, especially in non-standard shapes and sizes that cannot be efficiently packaged in standardized casings.
Innovation Solution
A battery cell design featuring a 3D-shaped core with an outer conductive shell that conforms to the shape of the core, utilizing a toroidal or randomly shaped metal foam with embedded active materials and a distributed anode current collector, which enhances electronic conductivity and eliminates the need for pre-formed shells, allowing for efficient packaging in odd-shaped devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a long conduction path through conductive additives is used in traditional battery cells, then the battery cell can maintain a simple structure with standard shapes, but the current delivery becomes slow and power output is limited due to electronic traffic jams
Solution Approach 1:
The patent transitions from traditional planar electrode structures to a three-dimensional battery architecture where the anode is distributed throughout the volume of the cathode. This dimensional change creates multiple conduction pathways and eliminates long electron travel distances, resolving the contradiction between structural simplicity and high power output.
Solution Approach 2:
The battery is segmented into discrete functional components (cathode particles, anode material, conductive additives) that are distributed throughout the cell volume. This segmentation allows electrons to travel shorter distances through conductive networks formed by conductive additives positioned strategically between cathode particles, improving current delivery while maintaining structural organization.
2Ease of manufacture
If standard cylindrical or rectangular battery cases are used, then manufacturing is simplified with pre-formed casings, but the battery cannot be efficiently packaged in odd-shaped devices like IoT devices
Solution Approach 1:
The patent employs a flexible polymer casing that can be formed into various shapes and sizes to match the contours of different devices. This flexible shell replaces rigid pre-formed metal casings, enabling the battery to be efficiently packaged in odd-shaped devices while maintaining ease of manufacture through thermforming or injection molding processes.
Solution Approach 2:
The battery architecture allows variation in physical parameters such as shape, size, and internal component distribution to adapt to different device requirements. The polymer casing can be thermformed into various geometries, and the 3D distributed anode configuration can be adjusted to fit different volume constraints, providing versatility without sacrificing manufacturing efficiency.
3Device complexity
If electrons travel through long conduction paths in conductive additives, then the battery cell structure remains simple, but charge time increases due to slow electron permeation through active material
Solution Approach 1:
By distributing the anode throughout the 3D volume of the cathode rather than using a planar configuration, the patent creates multiple short conduction pathways for electrons. This dimensional restructuring reduces the distance electrons must travel through conductive additives and active material, significantly decreasing charge time while maintaining structural simplicity.
Solution Approach 2:
The battery is divided into numerous small cathode particles with distributed anode material and conductive additives positioned between them. This segmentation creates many parallel conduction pathways, allowing electrons to travel shorter distances simultaneously through multiple routes, thereby reducing overall charge time without complicating the fundamental structure.
Data Source
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AI summary
Described is an apparatus comprising: a randomly shaped cathode; an anode current collector positioned in the randomly shaped cathode; and an outer conductor coupling the randomly shaped cathode, the outer conductor wrapping the randomly shaped cathode. A method is provided which comprises: forming a flat or tubular core to operate as an anode current collector; forming a randomly shaped cathode over the flat or tubular core; and applying an outer conductive skin over the randomly shaped cathode. Described is a system which comprises a memory; a processor coupled to the memory; and a battery to provide power to the memory and the processor, the battery according to the apparatus described above.