Curved Battery Cell Thickness Layout for Shape Retention
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Solution Overview
Problem
Batteries designed for portable electronic devices with curved form factors face challenges in maintaining their curved shape due to residual stress and strain in the electrode materials, leading to deflection and loss of curvature.
Innovation Solution
The battery design involves an anode and cathode substrate with specific curvatures and thicknesses, where the substrate with the larger curvature has a greater thickness, and a separator is placed between the anode and cathode to maintain the curved geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the battery is designed with a curved form factor to match portable electronic devices, then the battery can achieve desired packaging size and form factor compatibility, but residual stress and strain in electrode materials cause the battery to deflect and lose its curved shape
Solution Approach 1:
The patent applies different thicknesses to different substrates within the battery assembly. Specifically, when the anode substrate has a first curvature and the cathode substrate has a second curvature, the substrate with the larger curvature is made thicker. This local variation in thickness compensates for residual stresses differently across the battery structure, allowing the curved shape to be maintained without uniform thickness constraints.
Solution Approach 2:
The patent changes the thickness parameter of substrates based on their curvature characteristics. By making the substrate with larger curvature thicker, the design adjusts physical parameters to balance internal stresses. This parameter modification allows the battery to maintain its curved form factor while compensating for the deflection caused by residual stresses in electrode materials.
2Ease of manufacture
If uniform thickness is used for all substrates in the battery, then manufacturing is simplified, but the battery cannot effectively compensate for residual stress and strain, leading to shape deflection
Solution Approach 1:
Instead of uniform thickness, the patent implements local quality by varying substrate thickness according to curvature requirements. The substrate experiencing greater curvature is made thicker to provide additional structural support and stress compensation. This approach maintains manufacturing feasibility while significantly improving shape stability and reducing deflection from residual stresses.
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
Examples are disclosed herein that relate to curved batteries. One example provides a battery comprising an anode arranged on an anode substrate, a cathode arranged on a cathode substrate, the anode substrate being curved at a first curvature and the cathode substrate being curved at a second curvature, and a separator between the anode and the cathode. A thickness of the anode substrate and a thickness of the cathode substrate are determined based on the curvature of the respective substrate, such that the one of the anode substrate and the cathode substrate with a larger curvature has a larger thickness.