Flexible Battery Unit Cell Segmentation and Sealing
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Solution Overview
Problem
There is a growing demand for miniaturized and lightweight batteries to power small-sized mobile electronic devices, and existing batteries do not efficiently utilize space or provide the necessary flexibility and protection against external environments.
Innovation Solution
A flexible battery design featuring a first and second substrate with unit cells electrically connected via conductive patterns and active material layers, sealed by sealing members to prevent electrolyte leakage and enhance mechanical strength, allowing the battery to be bent or wound without external bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional battery designs are used, then energy density is achieved, but space utilization efficiency is poor and flexibility is limited
Solution Approach 1:
The battery is divided into multiple unit cells (first unit cell, second unit cell, etc.) that are arranged in parallel between the substrates. Each unit cell contains separate active material layers and conductive patterns, allowing modular configuration that optimizes space utilization while maintaining flexibility through the segmented structure.
Solution Approach 2:
The battery employs flexible substrates (first substrate and second substrate) as the structural foundation, replacing rigid housings with thin, bendable films. This enables the battery to be bent or wound without compromising structural integrity, directly providing the required flexibility and improving space utilization in compact devices.
2Device complexity
If unit cells are electrically connected without sealing members, then device complexity is reduced, but electrolyte leakage prevention is compromised
Solution Approach 1:
The sealing members serve dual functions: they electrically connect adjacent unit cells (replacing separate bus bars) and simultaneously seal the boundaries between unit cells to prevent electrolyte leakage. This merging of electrical connection and sealing functions into a single component reduces structural complexity while maintaining reliability.
3Reliability
If external bus bars are used for electrical connection, then electrical connectivity is ensured, but mechanical robustness and flexibility are reduced
Solution Approach 1:
The design extracts and eliminates external bus bars from the battery structure. Instead, electrical connectivity is achieved through conductive patterns formed directly on the flexible substrates and through sealing members that connect unit cells internally. This removal of external rigid components enhances both mechanical robustness and flexibility while maintaining electrical connectivity.
4Volume of moving object
If miniaturized battery design is implemented, then device size is reduced, but space utilization efficiency and protection are compromised
Solution Approach 1:
The flexible substrates act as both the structural framework and protective barrier for the miniaturized battery. These thin film substrates enclose the unit cells, providing protection against external environments (moisture, oxygen) while enabling the compact, miniaturized design. The flexible nature allows the small battery to be conformally mounted in various device configurations.
Data Source
AI summary
A flexible battery includes a first substrate, a second substrate, and a first unit cell and a second unit cell arranged between the first substrate and the second substrate in lengthwise directions of the first substrate and the second substrate, the first and second unit cells being electrically connected to each other.