Conformable Battery Pack Assembly for Wearable Sensor Comfort
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Solution Overview
Problem
Existing portable battery packs are uncomfortable and aesthetically undesirable due to their rigid structure and bulging design when worn on the body, and they require inconvenient connection cords for power delivery.
Innovation Solution
A conformable battery pack assembly with an array of electrochemical cells embedded in a flexible outer shell, integrated with an electronic component such as a sensor, and a direct interconnection for enhanced user comfort and flexibility, allowing the battery pack to be molded around the cells for a skin-like feel and seamless integration into clothing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard plastic outer shell is used for the battery pack, then structural strength and protection are improved, but comfort and flexibility deteriorate
Solution Approach 1:
The patent replaces the traditional hard plastic outer shell with a flexible outer shell that can conform to the body's surface. This flexible shell maintains sufficient structural strength to protect the battery cells while providing comfort and flexibility when worn on the body, directly resolving the contradiction between strength and wearability comfort.
2Ease of manufacture
If a rigid battery pack structure is used, then manufacturing simplicity is improved, but adaptability to body contours deteriorates
Solution Approach 1:
The flexible outer shell is designed to conform to body contours while maintaining a relatively simple manufacturing process. The shell can be molded to fit various body shapes and can be stretched or bent without compromising structural integrity, providing adaptability to different body parts while keeping manufacturing feasible.
Solution Approach 2:
The patent utilizes materials with specific mechanical properties (flexibility, elasticity) that allow the outer shell to change its shape and conform to body contours. By selecting materials with appropriate tensile strength and elasticity parameters, the battery pack achieves adaptability to body surfaces while maintaining manufacturing simplicity through standardized material selection and molding processes.
3Reliability
If connection cords are used for power delivery, then electrical connection reliability is improved, but convenience and ease of operation deteriorate
Solution Approach 1:
The patent removes the connection cord from the battery pack design, extracting this component entirely. Instead of using a cord for power delivery, the invention integrates wireless power transfer functionality directly into the flexible battery pack, eliminating the need for physical connection cords and significantly improving convenience while maintaining reliable electrical connection through contactless power transfer.
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 solution provides a comfortable, flexible power source that can be worn for extended periods without irritation, maintains electrical performance through stretching and bending, and allows for safe laundering of smart clothing incorporating the battery pack.
Implementation Method 1
the flexible outer shell material has a hardness as defined by ASTM D2240-15 of between HOOO-S 10 and 90A, preferably between HOO-5 and 30A, and more preferably between OO-10 and OO-50
Data Source
AI summary
A battery pack assembly includes an array of individual electrochemical cells electrically connected to one another. The array of individual electrochemical cells is embedded and encapsulated by a matrix of conformable material and the matrix of conformable material provides a protective outer shell. A sensor is electrically connected to the array.