Integrated Circuit Substrate Battery Separator Design
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Solution Overview
Problem
Existing lithium battery systems face challenges in flexibility and manufacturing costs due to the need for precise alignment of tabs and contacts, which limits the portability and reliability of electronic devices, and the separate packages for batteries and functional modules increase material and manufacturing costs.
Innovation Solution
The integration of a lithium battery system using a circuit substrate as a separator, which includes a circuit substrate with a separating area, electrode substrates, and package units, allowing for flexible integration on a circuit board with enhanced thermal stability and mechanical characteristics, eliminating the need for solder pads and reducing packaging costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs and contacts are precisely aligned to ensure reliable electricity supply, then reliability is improved, but manufacturing precision requirements increase and manufacturing costs increase
Solution Approach 1:
The patent combines the battery package unit and functional module package into a single integrated package structure. The circuit substrate serves dual purposes as both the functional module substrate and the battery separator, eliminating the need for separate alignment between tabs and contacts. This merging of functions and structures directly resolves the alignment precision issue while maintaining reliable electrical connection.
Solution Approach 2:
The circuit substrate performs multiple functions: it serves as the substrate for the functional module, as the separator for the battery, and as the structural element that provides alignment. This multi-functionality eliminates the need for separate alignment mechanisms and reduces manufacturing precision requirements while ensuring reliable electricity supply.
2Reliability
If tabs and contacts are precisely aligned to maintain stable electricity supply, then reliability is improved, but flexibility is reduced
Solution Approach 1:
By integrating the battery and functional module into a single package unit with a shared circuit substrate, the invention eliminates rigid alignment requirements. The combined structure allows the entire assembly to be flexible while maintaining stable electrical connection, as the integrated design removes the need for separate alignment interfaces that would constrain flexibility.
3Adaptability or versatility
If conductive wires are used to provide flexibility between tabs and contacts, then flexibility is improved, but manufacturing complexity increases and reliability decreases
Solution Approach 1:
The patent eliminates the need for separate conductive wires by integrating the electrical connection function into the circuit substrate itself. The substrate serves as both the structural support and the electrical conductor, reducing device complexity while maintaining flexibility. This merging of structural and electrical functions removes the vulnerability of separate wires to bending damage.
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
This solution provides a flexible, cost-effective, and thermally stable electricity supply system that can withstand repeated bending, enabling efficient mass production and reducing manufacturing costs by integrating the battery system on a circuit substrate, while maintaining reliable ion migration and electrical performance.
Implementation Method 1
The circuit substrate has at least one separating area. The first electrode substrate is disposed on one side of the circuit substrate and includes a first current collector and a first active material layer. The first active material layer is disposed opposed to the separating area and is located between the separating area and the first current collector. The second electrode substrate is disposed on another side of the circuit substrate
Implementation Method 2
The active material layers 12 and 13 are separated by a separator 11 to prevent short circuit between the active material layers 12 and 13. The active material layers configured to perform conversation of chemical energy into electrical energy
Implementation Method 3
the battery 1 includes a package unit 16 for enclosing various components of the battery 1 to prevent moisture intake and electrolyte leakage of the battery 1
Implementation Method 4
The conductors 14 and 15 are configured to collect currents and to form an electrical path between the active material layers 12 and 13 and a functional module 2
Data Source
AI summary
An electricity supply system includes a circuit substrate, a first electrode substrate, a second electrode substrate, a first package unit, and a second package unit. The circuit substrate includes at least a separating area. The first electrode substrate includes a first current collector and a first active material layer, which is disposed opposed to the separating area and is located between the separating area and the first current collector. The second electrode substrate includes a second current collector and a second active material layer, which is disposed opposed to the separating area and is located between the separating area and the second current collector. The first and second package units are located between the first electrode substrate, the second electrode substrate and the circuit substrate respectively.