Flexible Battery Foil Folded Meander Pattern
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Solution Overview
Problem
Current low volume high energy density batteries, such as those for medical implants, face challenges in achieving sufficient volumetric energy density due to packaging constraints, leading to short operational times for devices like ultra-low power radios.
Innovation Solution
A battery design featuring solid state Li-ion battery elements spaced along a flexible polyimide carrier foil, folded in a meander pattern to minimize volume and maximize energy density, with pairs of battery elements arranged back-to-back and connected in series, parallel, or both, to achieve high volumetric energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery volume is reduced to meet implantable device requirements, then the device size is reduced, but the volumetric energy density decreases rapidly due to packaging taking up a larger fraction of the battery volume
Solution Approach 1:
The patent transitions from traditional planar battery layouts to a three-dimensional stacked configuration. Multiple battery elements are arranged in layers along a flexible carrier foil and folded into a compact stack, effectively utilizing vertical space and achieving higher volumetric energy density in smaller volumes suitable for implantable devices
Solution Approach 2:
The patent implements a nested structure where battery elements are stacked within a compact folded configuration. The carrier foil is folded back on itself multiple times, with battery elements nested in successive layers, creating a space-efficient arrangement that maximizes energy density while minimizing overall battery volume
2Volume of moving object
If the battery volume is reduced to meet implantable device requirements, then the device size is reduced, but the operational duration decreases due to insufficient energy capacity
Solution Approach 1:
By stacking battery elements in multiple layers along the folded carrier foil, the patent increases the total energy capacity within a compact volume. This three-dimensional arrangement allows sufficient energy storage for extended operational duration while maintaining the small size required for implantable devices
Solution Approach 2:
The patent divides the battery into multiple discrete elements (at least two) that are stacked in series or parallel configurations. This segmentation allows optimization of both voltage and capacity while maintaining a compact overall structure suitable for long-duration operation in implantable devices
3Device complexity
If traditional battery packaging is used, then the battery structure is simple, but the volumetric energy density is low due to excessive packaging volume
Solution Approach 1:
The patent uses a flexible polyimide carrier foil as the battery structure backbone. This thin, flexible film serves as both the structural support and the mounting substrate for battery elements, eliminating the need for bulky rigid packaging and significantly reducing overall battery volume while maintaining structural integrity
Solution Approach 2:
The patent employs a folded stacked configuration that transforms a two-dimensional foil layout into a three-dimensional compact structure. This approach minimizes packaging volume by efficiently utilizing vertical space and arranging battery elements in a space-optimal manner
Data Source
AI summary
A battery comprises a carrier foil, with solid state battery elements spaced along the foil and mounted on opposite sides of the foil in pairs, with the battery elements of a pair mounted at the same position along the foil. The carrier foil is folded to define a meander pattern with battery element pairs that are adjacent each other along the foil arranged back to back.