Folding Battery Sheet Layout for Compact High-Voltage Storage
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Solution Overview
Problem
Existing stacked batteries face challenges in miniaturization and maintaining high capacity, with metal-air batteries experiencing performance degradation due to metal electrode deterioration, making long-term storage and compact design difficult.
Innovation Solution
A sheet for folding batteries with pre-arranged electrolyte and electrode elements, featuring through holes and integrated electrolyte layers, allows for folding into a compact high-voltage battery, preventing performance degradation until use and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If metal-air battery is used to achieve high capacity and small size, then battery capacity and size are improved, but metal electrode deteriorates due to contact with electrolyte causing performance degradation
Solution Approach 1:
The battery is divided into multiple independent stacks, each containing separated electrode and electrolyte parts. The electrodes are arranged on one surface of the sheet while electrolytes are arranged on the other surface, physically segmenting the components to prevent direct contact and deterioration during storage.
Solution Approach 2:
The electrode and electrolyte parts are pre-arranged in a specific pattern on the sheet before folding. The intended fold lines are pre-marked to guide the folding process, ensuring proper alignment of electrodes with electrolytes only when the battery is activated, preventing premature contact and degradation.
2Power
If stacked battery structure is used to increase voltage by changing number of stacks, then voltage is improved, but battery size and complexity increase
Solution Approach 1:
The battery transitions from a three-dimensional stacked structure to a two-dimensional sheet structure with parallel fold lines. Multiple electrode and electrolyte parts are arranged in parallel rows on the sheet, allowing voltage increase through additional stacks without proportionally increasing overall battery volume, as the structure folds compactly.
Solution Approach 2:
The battery uses a thin sheet structure as the base, with electrode and electrolyte parts arranged on opposite surfaces. This flexible sheet design allows the battery to be folded into a compact form factor, reducing volume while maintaining multiple stacks for high voltage output.
3Shape
If concentration cell structure is used to create folding battery, then folding capability is achieved, but manufacturing complexity increases and requires electrolyte concentration difference
Solution Approach 1:
The patent uses uniform electrolyte composition across all electrolyte parts, eliminating the need for different concentration levels. The simplification from heterogeneous (different concentrations) to homogeneous (same composition) electrolytes reduces manufacturing complexity while maintaining folding capability through the sheet structure with intended fold lines.
4Duration of action of stationary object
If metal-air battery is designed for long-term storage, then storage duration is improved, but metal electrode deteriorates over time causing performance degradation
Solution Approach 1:
The battery components are segmented into separate electrode parts and electrolyte parts arranged on opposite surfaces of the sheet. This physical separation prevents contact between the metal electrode and electrolyte during storage, eliminating deterioration pathways while maintaining long-term storage capability.
Solution Approach 2:
The electrode and electrolyte parts are pre-positioned in a non-contact arrangement on the sheet with intended fold lines indicating future activation points. This preliminary configuration allows long-term storage without degradation, as the components only come into contact when the battery is folded and activated for use.
Data Source
AI summary
A sheet for folding batteries includes a sheet that has one surface and another surface, and has a plurality of intended fold lines parallel to each other set on the sheet, at least one electrolyte part that is placed between a pair of the intended fold lines on the sheet, and a plurality of electrode parts that is placed, on the sheet, next to the electrolyte part with the intended fold line interposed therebetween. The electrolyte part includes a through hole provided between the one surface and the other surface of the sheet, and an electrolyte layer that is formed on the one surface and the other surface of the sheet so as to face each other across the through hole and is integrated via the through hole.