Flexible Battery Structure for Capacity Retention Under Flexion

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Solution Overview

Problem

Existing battery designs suffer significant capacity degradation due to weld failure, current collector tab tearing, and electrode/separator cracking under mechanical stress, particularly during flexion, leading to internal disconnection and capacity loss.

Innovation Solution

Implementing 'buried welds', compliant current collector tabs, and structured battery cells with corrugated designs to enhance mechanical resilience, thereby protecting critical components from damage during flexion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional battery designs are used, then manufacturing is simpler, but weld failure and component damage occur under mechanical stress

Engineering Contradiction:

Improveweld reliabilityVSAvoidbattery structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The weld is nested within the adhesive layer, creating a buried weld structure where the adhesive encapsulates the weld zone. This protects the weld from mechanical stress while maintaining electrical connectivity, resolving the contradiction between weld reliability and structural complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

An adhesive intermediary layer is introduced between the current collector and external elements, serving as both a mechanical buffer and electrical conductor. This adhesive layer absorbs mechanical stress and protects the underlying weld and current collector from damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If rigid battery structures are used, then structural stability is better, but capacity degradation occurs during flexion

Engineering Contradiction:

Improvecapacity retentionVSAvoidstructural strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The battery structure transitions from rigid to flexible by changing the mechanical properties of components - using flexible current collectors, compliant tabs with folded geometries, and adhesive layers that can accommodate bending. This enables capacity retention during flexion while maintaining sufficient structural integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The current collector tab is segmented through multiple folds, creating a flexible articulated structure that can bend without breaking. This segmented design maintains electrical connectivity while accommodating mechanical flexion, preventing capacity degradation.

Inventive Principle:

Principle #1Segmentation

3Reliability

If current collector tabs are made compliant with folds, then mechanical resilience improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemechanical resilienceVSAvoidtab fold precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The current collector tab transitions from a static rigid structure to a dynamic flexible structure with folds. The folds create articulated joints that allow the tab to adapt to mechanical stresses, improving resilience while the adhesive burial simplifies the need for precise fold positioning.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The adhesive layer acts as a sacrificial protective element that absorbs manufacturing tolerances. Minor imprecisions in tab fold positioning are compensated by the adhesive's ability to conform and maintain electrical connectivity, reducing the stringency of manufacturing precision requirements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Object-affected harmful factors

If adhesive is used to hermetically seal the battery, then protection from environmental factors improves, but energy density may be impacted

Engineering Contradiction:

Improveprotection from moistureVSAvoidenergy density

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

A thin flexible adhesive film is used for hermetic sealing instead of bulky rigid enclosures. This thin-film approach provides effective moisture protection while minimizing the volume occupied by non-active materials, preserving energy density.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The adhesive sealing layer is formulated as a composite material combining moisture barrier properties with electrical conductivity. This dual-function adhesive provides environmental protection without requiring additional separate components, maintaining energy density.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250273736A1Flexible battery

Publication Date: 2025.08.28 ANTHRO ENERGY INC

AI summary

A flexible battery can include a cathode current collector; a cathode disposed on the cathode current collector; an anode current collector; an anode disposed on the anode current collector; a separator disposed between the cathode and the anode; an electrolyte interspersed within the cathode, the separator, and the anode; and a casing enclosing the cathode current collector, the cathode, the separator, the anode, and the anode current collector.