Non-rectangular Battery Cells for Irregular Device Packaging
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Solution Overview
Problem
Existing battery pack architectures in portable electronic devices are limited by the use of rectangular cells, which inefficiently utilize space and fail to accommodate non-rectangular device shapes, leading to suboptimal packaging efficiency, capacity, and form factor.
Innovation Solution
The design of non-rectangular battery cells with electrode sheets of different dimensions arranged in stacked configurations, such as toroidal, L-shaped, triangular, or pyramidal designs, electrically coupled in parallel and enclosed in a pouch with conductive tabs for efficient space utilization, allowing the battery to fit within curved or irregular device enclosures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rectangular battery cells are used in traditional battery pack architectures, then manufacturing and electrical configuration are simplified, but space utilization efficiency deteriorates and free space cannot be utilized
Solution Approach 1:
The battery pack is divided into multiple individual battery cells, each with its own pouch enclosure. This segmentation allows each cell to be independently shaped and sized to fit specific spaces within the portable device, while maintaining standardized manufacturing processes for each cell unit.
Solution Approach 2:
The battery cells are designed with non-rectangular, asymmetric shapes that conform to the irregular internal spaces of portable electronic devices. This asymmetry enables better space utilization by matching the contour of available device space rather than forcing rectangular cells into irregular gaps.
2Reliability
If multiple rectangular cells are arranged in series/parallel configurations, then electrical requirements are met, but the battery pack cannot adapt to non-rectangular device enclosures
Solution Approach 1:
Each battery cell within the pack can have different dimensions and shapes tailored to specific locations within the device enclosure. This local customization allows the battery system to adapt to non-rectangular device forms while maintaining proper electrical series/parallel configurations through selective cell placement and connection.
3Quantity of substance
If electrode sheets are arranged in non-rectangular stacked configurations, then packaging efficiency and capacity increase, but manufacturing complexity and electrical coupling difficulty increase
Solution Approach 1:
Electrode sheets are stacked in nested configurations where smaller sheets are placed within the boundaries of larger sheets, creating compact non-rectangular arrangements. This nesting approach maximizes the use of available space within each cell pouch while maintaining organized electrical connections through systematic tab arrangement.
Data Source
AI summary
The disclosed embodiments relate to a battery cell which includes a set of electrode sheets of different dimensions arranged in a stacked configuration to facilitate efficient use of space inside a portable electronic device. For example, the electrode sheets may be arranged in the stacked configuration to accommodate a shape of the portable electronic device. The stacked configuration may be based on a non-rectangular battery design such as a toroidal design, an L-shaped design, a triangular design, a pie-shaped design, a cone-shaped design, and/or a pyramidal design.