Battery Assembly with Shared Encapsulation Layer
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Solution Overview
Problem
Mobile electronic devices require improved batteries with higher power density to accommodate increasing functionalities, as existing batteries struggle to provide sufficient power due to their bulk and limited energy output relative to volume.
Innovation Solution
A battery assembly comprising two batteries with their active layers facing each other and sharing a thin encapsulation layer, which is less than 10 μm in thickness, allowing for electrical connection in parallel and symmetrical arrangement, enhancing mechanical protection and electric insulation while reducing overall volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single battery is used with conventional encapsulation, then mechanical protection and electric insulation are provided, but volume power density is limited due to thicker encapsulation requirements
Solution Approach 1:
Two batteries are stacked and merged by sharing a common encapsulation layer between them. The encapsulation layer is deposited on one battery, then the second battery is stacked against it, creating a unified structure where one encapsulation layer serves dual protective functions for both batteries, thereby reducing total encapsulation material and increasing volume power density
Solution Approach 2:
The patent employs ultrathin encapsulation layers with thickness between 1-10 μm (preferably 3-5 μm) made from polymer and oxide materials. These thin film structures provide adequate mechanical protection and electric insulation while minimizing volume consumption, enabling higher volume power density compared to conventional thicker encapsulation
2Quantity of substance
If battery volume is reduced to increase power density, then energy output relative to size improves, but mechanical protection and electric insulation may be compromised
Solution Approach 1:
The encapsulation layer is constructed as a composite structure combining polymer materials ( providing mechanical flexibility and protection) and oxide materials (providing excellent electric insulation and chemical stability). This composite approach enables ultrathin encapsulation (1-10 μm) to simultaneously deliver adequate mechanical protection and electric insulation while minimizing volume
Solution Approach 2:
By stacking two batteries and sharing a common encapsulation layer, the structure achieves volume reduction while maintaining protective functions. The shared encapsulation layer is reinforced by the stacking arrangement and polymerization anneal process, ensuring adequate protection despite reduced thickness
3Quantity of substance
If multiple batteries are stacked to increase power density, then volume power density improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct sequential steps: forming first battery with encapsulation layer deposition, then forming second battery, stacking them together, and performing polymerization anneal. This segmentation allows each step to be optimized independently while maintaining overall process manageability and scalability
Solution Approach 2:
The encapsulation layer is deposited on the first battery before stacking, and the polymerization anneal is performed after stacking to simultaneously cure both batteries' encapsulation layers. This preliminary and sequential action approach streamlines the manufacturing process by combining operations rather than treating each battery separately
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 battery assembly achieves a higher volume power density, up to 260 Wh/l, compared to single batteries, by optimizing the encapsulation layer's thickness and structure, thereby improving the energy output relative to the device's size.
Implementation Method 1
the encapsulation layer has a thickness between 1 μm and 10 μm, preferably between 3 μm and 5 μm
Implementation Method 2
performing a polymerization anneal
Data Source
AI summary
The disclosure concerns a battery assembly including two batteries having their active layers facing each other and sharing an encapsulation layer.