Pin-Shaped Battery Module Curvature via Hinge Connectors
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Solution Overview
Problem
Existing rechargeable batteries face challenges in imparting curvature due to their design, particularly in small cylindrical and square-shaped forms, which limits their flexibility and application in mobile devices.
Innovation Solution
A rechargeable battery module featuring pin-shaped batteries with a diameter of 2-5 mm, where caps are mechanically and electrically connected using a hinge connector system, allowing for curvature adjustment across the length direction, enabling flexible bending capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional square-shaped or cylindrical rechargeable batteries are used, then the battery structure is simple and easy to manufacture, but the battery cannot effectively impart curvature and has limited flexibility
Solution Approach 1:
The battery is divided into multiple pin-shaped battery cells (first rechargeable battery, second rechargeable battery, etc.) arranged in parallel. Each cell is independently connected to caps, allowing individual curvature adjustment while maintaining overall battery function. This segmentation enables the battery module to achieve flexible bending without requiring each individual cell to be complex.
Solution Approach 2:
The connector is designed with movable caps that can change position relative to each other, enabling dynamic curvature adjustment. The caps are movable relative to the connector such that a curvature between the corresponding rechargeable batteries changes in a direction crossing the length direction, transforming the rigid battery structure into a dynamic, adaptable system.
2Adaptability or versatility
If pin-shaped batteries with small diameter (2-5 mm) are used to achieve curvature, then the flexibility and curvature capability are improved, but the manufacturing precision and assembly complexity increase
Solution Approach 1:
The battery system is segmented into multiple pin-shaped cells with small diameters (2-5 mm), where each cell's small size enables curvature while the modular arrangement compensates for manufacturing tolerances. The parallel configuration allows the system to achieve desired curvature even with variations in individual cell dimensions.
Solution Approach 2:
The cap serves as an intermediary component that connects adjacent pin-shaped batteries and provides a interface for curvature adjustment. The connector with movable caps mediates between the precision requirements of small-diameter cells and the flexibility requirements, allowing curvature change without demanding extreme manufacturing precision on each cell.
3Adaptability or versatility
If multiple caps are used to connect adjacent batteries with a hinge connector, then the curvature adjustment capability is improved, but the device complexity and number of components increase
Solution Approach 1:
The cap structure merges multiple functions: electrical connection between batteries, mechanical support for curvature, and interface for the hinge connector. By combining these functions into a single cap component, the system achieves curvature adjustment capability without proportionally increasing overall complexity.
Solution Approach 2:
The connector is designed as a universal component that can connect multiple caps and accommodate curvature adjustments across different battery configurations. The hinge connector mechanism provides multi-functionality by enabling both electrical connection and mechanical curvature adjustment, reducing the need for separate specialized components.
Data Source
AI summary
A rechargeable battery module that effectively imparts a curvature using a rechargeable battery formed as a pin-shaped rechargeable battery with a very small diameter is provided. The rechargeable battery module includes a plurality of rechargeable batteries arranged in parallel, wherein each rechargeable battery comprises a case and terminals that extend from respective ends of the case along a length direction of the case. The module includes a plurality of caps, wherein each cap is coupled to an end of a rechargeable battery of the plurality of rechargeable batteries and is electrically connected to one of the terminals of the rechargeable battery. The module also includes a connector on each cap connecting adjacent caps coupled to corresponding rechargeable batteries. The adjacent caps are moveable relative to the connector such that a curvature between the corresponding rechargeable batteries changes in a direction crossing the length direction.