Flexible Battery Encapsulation Structure for Micro-Crack Detection
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Solution Overview
Problem
Flexible batteries are prone to micro-cracks due to bending, leading to issues such as liquid leakage and swelling, which pose safety hazards and are difficult to detect.
Innovation Solution
A flexible battery design with a first flexible encapsulation layer having a higher elastic modulus than a second flexible encapsulation layer, featuring a concave-convex structure to distribute stress and a crack detection wiring for early detection of micro-cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the flexible battery is bent, then flexibility is improved, but micro-cracks occur at the edge leading to liquid leakage and swelling
Solution Approach 1:
The patent uses a flexible encapsulation layer made of thin film material that can bend without breaking. The encapsulation layer completely wraps the battery cell, providing mechanical protection while maintaining flexibility. The thin film structure allows the battery to be bent without causing micro-cracks at the edges, thus preventing liquid leakage and swelling while preserving encapsulation integrity.
Solution Approach 2:
The flexible encapsulation layer is constructed as a composite structure with multiple layers including a flexible substrate layer and a protective coating layer. This composite material design combines the flexibility of the substrate with the crack resistance and chemical stability of the protective coating, enabling the battery to withstand bending stresses without developing micro-cracks that would compromise encapsulation.
2Device complexity
If a single-layer encapsulation structure is used, then device complexity is reduced, but stress distribution during bending is insufficient causing micro-cracks
Solution Approach 1:
The encapsulation structure is divided into multiple functional layers: a flexible substrate layer providing bendability, a protective coating layer preventing micro-crack formation, and a sealing layer preventing liquid leakage. This segmentation allows each layer to perform its specific function optimally, with the substrate absorbing bending stress and the coating layer resisting crack propagation, thereby improving crack resistance without significantly increasing overall device complexity.
Solution Approach 2:
Different regions of the encapsulation structure have different material properties optimized for their specific functions. The flexible substrate layer has high elasticity to accommodate bending, while the protective coating layer has high tensile strength to prevent micro-cracks. This local differentiation of material quality allows the structure to handle bending stresses effectively while maintaining a relatively simple overall design.
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 design enhances bending resistance and safety by reducing micro-crack formation and enables accurate crack detection, ensuring reliable operation.
Implementation Method 1
an elastic modulus of the first flexible encapsulation layer is greater than that of the second flexible encapsulation layer
Implementation Method 2
a second flexible encapsulation layer, including a protruding portion covering the battery cell and a recessed portion located between adjacent battery cells
Data Source
AI summary
The present disclosure provides a flexible battery and an electronic device, belonging to the technical field of batteries. The flexible battery of the present disclosure includes a flexible encapsulation structure, a plurality of battery cells and a second flexible encapsulation layer. The plurality of battery cells are arranged on a side of the first flexible encapsulation layer and arranged at intervals along a first direction. The second flexible encapsulation layer includes a protruding portion covering the battery cell and a recessed portion located between adjacent battery cells. An elastic modulus of the first flexible encapsulation layer is greater than that of the second flexible encapsulation layer.