Stacked Thin Cell Battery with Flexible Resin Interlayers
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Solution Overview
Problem
Existing thin cell batteries, as described in US 2009/0214899 A1 and U.S. Pat. No. 5,705,293, often fail to provide sufficient capacity and voltage due to limitations in their design and materials.
Innovation Solution
A battery design that stacks multiple thin cells on a supporting substrate with resin layers of specific tensile strength (0.5 MPa to 10 MPa) between each cell, allowing for absorption of volume changes during charging and discharging, thereby enhancing capacity and voltage while preventing battery breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thin cell batteries are designed with conventional structures, then manufacturing is simplified, but capacity and voltage are insufficient
Solution Approach 1:
The battery is divided into multiple thin cells stacked in sequence, with each cell containing electrochemical materials. This segmentation allows the battery to achieve higher capacity through multiple smaller units while maintaining manageable structural complexity through standardized stacking
Solution Approach 2:
Multiple thin cells are nested within a single battery housing structure, with cells stacked vertically or horizontally. This nesting approach consolidates multiple electrochemical units into one integrated battery package, achieving higher overall capacity without proportionally increasing external dimensions
2Reliability
If rigid structures are used in battery assembly, then structural strength is improved, but volume changes during charging and discharging cause breakdown
Solution Approach 1:
Resin layers with specific tensile strength (0.5-10 MPa) are used as flexible intercell spacers between thin cells. These resin layers provide sufficient structural support while allowing the necessary volume expansion and contraction during charging and discharging cycles, preventing structural breakdown
Solution Approach 2:
The tensile strength of resin layers is optimized to a specific range (0.5-10 MPa) that balances structural support with flexibility. This parameter optimization ensures the battery can withstand mechanical stress while accommodating electrochemical volume changes
3Strength
If resin layers with high tensile strength are used between cells, then structural integrity is improved, but volume changes during charging and discharging are restricted
Solution Approach 1:
The tensile strength of resin layers is precisely controlled within the range of 0.5-10 MPa. This parameter optimization ensures the resin is strong enough to maintain structural integrity during assembly and handling, yet flexible enough to accommodate the natural volume changes that occur during electrochemical reactions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The battery achieves a higher capacity and voltage while maintaining reliability by using low-rigidity resin layers to absorb volume changes, ensuring the battery's structural integrity and performance.
Implementation Method 1
resin layers have 0.5 MPa to 10 MPa in tensile strength... allowing for absorption of volume changes during charging and discharging
Data Source
AI summary
A battery includes a supporting substrate, resin layers, and a plurality of cells. Each resin layer includes a first resin and has 0.5 MPa to 10 MPa in tensile strength. The cells are stacked on the supporting substrate with the resin layers between the cells.