Conformable Battery Pack Assembly With Multi-Axis Flexing
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Solution Overview
Problem
Existing portable battery packs are uncomfortable and aesthetically undesirable due to their rigid design, causing bulges in clothing and requiring inconvenient connection cords, while lacking sufficient flexibility and conformability to be worn on the human body effectively.
Innovation Solution
A conformable battery pack assembly featuring an array of individual electrochemical cells electrically connected and encapsulated within a flexible outer shell with multiple bending axes, allowing for extension, bending, and torsion without material stress, and optionally including an electronic component and slits for enhanced flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard plastic outer shell is used to contain the battery pack, then structural strength and protection are improved, but comfort and conformability to the body deteriorate
Solution Approach 1:
The patent replaces the traditional hard plastic outer shell with a flexible outer shell made of elastomeric material. This flexible shell encapsulates the battery cells and electrical connections, providing both structural integrity and conformability to body contours. The elastomeric material allows the battery pack to bend and flex while maintaining protection of internal components, directly resolving the contradiction between strength and comfort.
2Ease of manufacture
If rigid battery pack structure is used, then manufacturing simplicity is improved, but adaptability to different body positions and wearable configurations deteriorates
Solution Approach 1:
The patent changes the mechanical parameters of the outer shell from rigid to flexible by using elastomeric material with specific durometer ratings (20-80 Shore A). This parameter change enables the battery pack to adapt to various body positions and wearable configurations while maintaining ease of manufacture through molding processes suitable for elastomeric materials.
3Reliability
If a connection cord is used to supply power to the device, then power transmission reliability is improved, but convenience and ease of use deteriorates
Solution Approach 1:
The patent merges the battery pack housing with the electrical connection interface by integrating wireless power transmission components (such as inductive coupling elements) directly into the flexible outer shell. This eliminates the need for separate connection cords while maintaining reliable power transmission to wearable devices through contactless energy transfer.
Data Source
AI summary
A conformable battery pack assembly includes an array of individual electrochemical cells electrically connected with one another. The array is surrounded and encapsulated by a flexible outer shell. The array is arranged geometrically so that there are at least three non-parallel bending axes.