Non-rectangular Battery Cell for Irregular Device Spaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery pack designs for portable electronic devices are limited by their rectangular shape, which fails to efficiently utilize non-rectangular or irregularly shaped spaces within the devices, leading to suboptimal packaging efficiency and capacity.
Innovation Solution
The development of a battery cell with a non-rectangular shape formed by removing material from the cathode and anode layers, allowing for a flexible pouch design that accommodates curved or irregular spaces, and featuring multiple thicknesses to fit various device enclosures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rectangular battery cells are used in conventional battery pack designs, then manufacturing and electrical configuration are simplified, but packaging efficiency and space utilization in portable electronic devices deteriorate
Solution Approach 1:
The battery cell is divided into multiple layers (first layer, second layer, third layer) that can be independently formed and then assembled. This segmentation allows each layer to be optimized for space efficiency while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
The invention transitions from conventional two-dimensional rectangular cells to a three-dimensional multi-layer structure. The layers are stacked vertically with conductive tabs extending through multiple layers, creating a non-rectangular overall shape that better fits irregular device spaces while maintaining ease of assembly.
2Device complexity
If rectangular battery cells are arranged in standard configurations, then electrical assembly is simplified, but adaptability to irregular device spaces deteriorates
Solution Approach 1:
The battery cell employs an asymmetric multi-layer structure where layers have different dimensions and configurations. The first, second, and third layers are arranged with varying orientations and sizes, creating an overall non-rectangular shape that adapts to irregular device spaces while maintaining systematic assembly procedures.
Solution Approach 2:
The conductive tabs serve multiple functions: they provide electrical connection between layers, act as structural support elements, and enable flexible electrical configurations (series, parallel, or series-parallel) within the multi-layer structure, making the design universally applicable to different device requirements.
3Ease of manufacture
If uniform thickness battery cells are used, then manufacturing is simplified, but flexibility to fit various device enclosures deteriorates
Solution Approach 1:
Different layers in the battery cell have different thicknesses and dimensions tailored to specific local requirements. The first layer may have greater thickness in certain regions while the second and third layers have reduced thickness, creating a non-uniform overall structure that fits irregular device enclosures while each individual layer maintains manufacturing simplicity.
Data Source
AI summary
The disclosed embodiments provide a battery cell. The battery cell includes a set of layers forming a non-rectangular shape, wherein the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating. The battery cell also includes a first conductive tab coupled to the cathode and a second conductive tab coupled to the anode. The layers are enclosed in a flexible pouch, and the first and second conductive tabs are extended through seals in the pouch to provide terminals for the battery cell. Furthermore, the non-rectangular shape is created by removing material from one or more of the layers.