Flexible Battery Matrix for Conformal Wearable Power
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Portable battery systems face challenges in increasing power capacity while maintaining user safety and reducing size and weight, as adding more battery cells or using higher capacity cells often results in increased size and weight, compromising mobility.
Innovation Solution
A conformal wearable battery system utilizing a flexible printed circuit board assembly with a grid-like pattern of physical connection sections, allowing battery cells to be folded and arranged in a three-dimensional matrix, with electrical connections made on the interior surface to minimize size and weight while maintaining power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional battery cells or higher capacity battery cells are included to increase power storage capability, then power capacity is improved, but size and weight increase, reducing mobility
Solution Approach 1:
The battery cells are arranged in a three-dimensional matrix configuration rather than a traditional two-dimensional planar arrangement. The flexible printed circuit board is folded along a bend axis to create a 3D structure with multiple layers, allowing battery cells to be positioned in three dimensions. This dimensional transformation enables increased power capacity by packing more cells into a compact volume without proportionally increasing weight, as the 3D arrangement optimizes space utilization and reduces overall system footprint.
Solution Approach 2:
The battery cells are nested within a folded flexible printed circuit board structure, where multiple layers of battery cells are stacked and interconnected through the folded PCB. The 3D matrix arrangement allows inner layers to be nested within outer layers, creating a compact nested configuration that maximizes power density while minimizing weight and volume.
2Quantity of substance
If additional battery cells or higher capacity battery cells are included to increase power storage capability, then power capacity is improved, but size increases, reducing mobility
Solution Approach 1:
The battery cells are arranged in a three-dimensional matrix configuration rather than a traditional two-dimensional planar arrangement. The flexible printed circuit board is folded along a bend axis to create a 3D structure with multiple layers, allowing battery cells to be positioned in three dimensions. This dimensional transformation enables increased power capacity by packing more cells into a compact volume without proportionally increasing weight, as the 3D arrangement optimizes space utilization and reduces overall system footprint.
3Reliability
If battery cells are arranged in a durable and sealed housing to protect from damage, then reliability is improved, but flexibility is reduced
Solution Approach 1:
The flexible printed circuit board serves as both the structural support and protective enclosure for the battery cells. The PCB is folded along a bend axis to create a 3D matrix configuration while maintaining flexibility. This flexible PCB structure provides protection for the battery cells through its durable construction while simultaneously enabling the battery to conform to different shapes and surfaces, thus maintaining adaptability and versatility.
Solution Approach 2:
The battery structure is designed to be dynamic and adaptable rather than rigid. The flexible printed circuit board can be folded and configured in different 3D arrangements, allowing the battery to adapt to different wear locations and application requirements. This dynamic configuration capability maintains flexibility while the durable PCB construction provides necessary protection for the battery cells.
Data Source
AI summary
A matrix of battery cell modules includes a flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) with a plurality of attachment sections for each of a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. Each battery cell may be joined with a flexible PCB via a welding process. The flexible PCBA is configured to fold along a bend axis so that the flexible PCBA is folded approximately in half. When affixed to the flexible PCBA, the plurality of battery cell modules and a circuitry module form a grid of physical components. When folded, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.