Conformal Wearable Battery Layout for Capacity and Shock Protection
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Solution Overview
Problem
There is a need in the mobile electrical power storage industry to increase power capacity while improving user safety and reducing the size and weight of portable battery systems, such as conformal wearable batteries, without compromising their mobility.
Innovation Solution
A conformal wearable battery system is designed with a matrix of battery cells arranged in a grid-like pattern, using a flexible printed circuit board assembly that can fold to reduce mechanical stresses and includes impact-absorbing members to mitigate shock and vibration, along with a sealed housing to prevent liquid ingress, utilizing materials like polycarbonate and thermoplastic elastomer for the shells and conductive components like brass, gold, or copper for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional battery cells or larger battery cells are used to increase power storage capability, then power capacity is improved, but size and weight increase reducing mobility
Solution Approach 1:
The battery system is divided into multiple individual battery cells arranged in a matrix, allowing the power capacity to be increased by adding more cells rather than using fewer large cells. This segmentation enables modular scaling of power capacity while maintaining manageable size and weight distribution across the conformal array.
Solution Approach 2:
The battery cells are arranged in a two-dimensional conformal matrix that can wrap around surfaces, transitioning from traditional three-dimensional bulk battery packages to a surface-distributed configuration. This dimensional change allows power capacity to scale across area rather than volume, improving the power-to-weight ratio and maintaining mobility.
2Quantity of substance
If additional battery cells or larger battery cells are used to increase power storage capability, then power capacity is improved, but size increases reducing mobility
Solution Approach 1:
The battery system is divided into multiple individual battery cells arranged in a matrix, allowing the power capacity to be increased by adding more cells rather than using fewer large cells. This segmentation enables modular scaling of power capacity while maintaining manageable size and weight distribution across the conformal array.
Solution Approach 2:
The battery cells are arranged in a two-dimensional conformal matrix that can wrap around surfaces, transitioning from traditional three-dimensional bulk battery packages to a surface-distributed configuration. This dimensional change allows power capacity to scale across area rather than volume, improving the power-to-weight ratio and maintaining mobility.
3Quantity of substance
If battery cells are arranged in a conformal matrix to improve power density, then power capacity per weight is improved, but mechanical stress and vulnerability to shock increase
Solution Approach 1:
Shock-absorbing members are positioned between adjacent battery cells to provide preemptive protection against mechanical shocks and vibrations. These cushioning elements absorb impact forces before they can damage the battery cells, enabling the conformal matrix configuration to maintain both high power density and mechanical durability.
Solution Approach 2:
The battery cells are enclosed in flexible pouches rather than rigid containers, allowing the conformal array to flex and deform under mechanical stress without structural failure. This flexible packaging maintains the compact high-density configuration while accommodating the mechanical stresses of wearable applications.
4Reliability
If a sealed housing is used to protect battery cells from environmental damage, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of sealing the entire battery array in a single complex housing, each battery cell is individually enclosed in its own sealed pouch. This segmentation of the sealing function simplifies manufacturing, as each cell can be packaged and sealed independently using standard processes, while the collective array achieves environmental protection.
Solution Approach 2:
Flexible sealed pouches made from laminated films are used to enclose each battery cell, providing effective environmental protection through thin, lightweight barriers. This approach achieves reliable sealing with simpler manufacturing compared to rigid housings, as the flexible pouches can be heat-sealed using conventional packaging equipment.
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 effectively increases power capacity, enhances user safety by minimizing size and weight, and maintains mobility by using flexible and impact-absorbing designs within a sealed and durable housing, ensuring reliable electrical connections and protection against environmental factors.
Implementation Method 1
a plurality of battery cells arranged in a grid-like pattern, where the plurality of battery cells have a positive terminal and a negative terminal to provide electricity through a transfer of electrons between the positive terminal and negative terminal
Implementation Method 2
impact absorbing members to absorb or reduce shock and vibration forces seen by the electronic members for a portable electrical power storage system
Implementation Method 3
a housing with an interior cavity that receives the plurality of battery cells... The perimeter region of the outward-facing surface of the contact component may be secured to the housing forming a sealed edge to prevent ingress of liquid into the interior cavity
Data Source
AI summary
A molded housing of a conformal wearable battery (CWB) encloses an electronic component and include an electrically conductive contact component embedded within an exterior wall to conduct electricity between an interior and an exterior of the casing. A flexible printed circuit board assembly (PCBA) for a CWB is enclosed in a cavity within the molded housing and includes attachment sections for a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. A visco-elastic shock-absorbing member installed between the upper and lower portion of the flexible PCBA when configured in a folded configuration. Each battery cell is joined to the flexible PCBA via a welding process. Each battery cell has a visco-elastic shock-absorbing member attached individually to each battery cell of the plurality of battery cells.