Flexible Multi-Cell Battery Bridge Design
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Solution Overview
Problem
There is a need for low-cost, low-profile, thin, and flexible battery solutions that can be mass-produced for applications requiring low power, such as smart labels, RFID tags, and other portable devices, as conventional batteries fail to provide adequate voltage, capacity, and cost-effectiveness.
Innovation Solution
A flexible battery design featuring multiple electrochemical cells connected in series or parallel, printed on a laminated substrate with a bridge portion for electrical coupling, using a current collector layer and liquid electrolytes, allowing for folding to reduce surface area and facilitate integration into small electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple electrochemical cells are connected in series or parallel on a single substrate, then voltage and capacity are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The battery is divided into multiple discrete electrochemical cells (first cell, second cell, etc.) that are independently formed on separate cell portions of the substrate. Each cell can be independently manufactured and then electrically connected through conductive bridges, allowing modular assembly that simplifies the overall manufacturing process while achieving desired voltage and capacity specifications through series or parallel connections.
Solution Approach 2:
The substrate serves multiple functions: it provides mechanical support for the electrochemical cells, acts as an electrical connection medium through integrated conductive bridges, and enables flexible configuration options (series or parallel connections). This multi-functionality reduces the need for separate components and simplifies the overall device structure despite containing multiple cells.
2Power
If conventional batteries are used, then adequate voltage and capacity are provided, but cost-effectiveness and integration capability into small devices deteriorate
Solution Approach 1:
Multiple electrochemical cells are merged onto a single flexible substrate, sharing common structural and electrical infrastructure. The conductive bridges and substrate serve multiple cells simultaneously, reducing material usage and manufacturing steps compared to assembling separate battery units. This integration maintains adequate power output while significantly improving cost-effectiveness for low-power applications.
Solution Approach 2:
The use of flexible substrates and thin-film electrochemical cells enables the battery to be manufactured using low-cost printing and deposition techniques. The flexible nature allows integration into small, thin electronic devices while maintaining manufacturing simplicity and cost-effectiveness, overcoming the limitations of conventional rigid batteries.
3Length of moving object
If thin and flexible battery design is implemented, then integration capability into small devices is improved, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The thin battery is segmented into multiple discrete cells formed on a flexible substrate. Each cell can be independently manufactured with standard precision tolerances, and the flexible substrate accommodates thermal expansion and manufacturing variations. This segmentation approach maintains manufacturing precision while achieving the desired thin and flexible form factor.
Solution Approach 2:
The invention changes the physical state and properties of the battery components by using flexible substrates and thin-film materials that can be deposited using printing techniques. This parameter change from rigid to flexible materials enables thin-profile construction while maintaining manufacturing precision through controlled deposition processes and flexible tolerance accommodation.
4Reliability
If electrochemical cells are electrically connected using rigid connections, then electrical conductivity is improved, but flexibility and foldability deteriorate
Solution Approach 1:
The electrical connections between electrochemical cells are implemented using flexible conductive bridges printed or deposited on the flexible substrate. These bridges maintain electrical conductivity through their conductive material composition while accommodating flexing and folding of the battery through their flexible substrate support. This resolves the contradiction by providing both electrical reliability and mechanical flexibility simultaneously.
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 enables the production of thin, flexible batteries with reliable performance across various temperatures, suitable for low-power applications, offering improved cost-effectiveness and integration capabilities, while maintaining high conductivity and durability.
Implementation Method 1
A first electrochemical cell is provided on the first cell portion, comprising a first anode and a first cathode, and a second electrochemical cell is provided on the second cell portion, comprising a second anode and a second cathode
Implementation Method 2
First and second liquid electrolytes are provided, respectively, in contact with the first and second electrochemical cells
Implementation Method 3
An electrical bridge electrically couples the first electrochemical cell to the second electrochemical cell in series or parallel
Data Source
AI summary
A flexible battery includes a first substrate layer with a first cell portion, a second cell portion, and a bridge portion connecting the first and second cell portions. An electrical bridge electrically couples a first electrochemical cell to a second electrochemical cell in series or parallel, and an electrical bridge is flexible and extends across the bridge portion of the first substrate layer. A second substrate layer is connected to the first substrate layer such that both of the first and second electrochemical cells are separately sealed. The flexible battery is configured to be folded over itself along the bridge portion such that the first and second electrochemical cells are arranged in a covering relationship. Optionally, an open gap area is disposed over the bridge portion of the first substrate to facilitate folding the flexible battery over itself along a line extending through the bridge portion.