Conformal Wearable Battery Housing and Folded Cell Matrix
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Solution Overview
Problem
There is a need to increase the power capacity of portable electrical power storage systems while improving user safety and reducing their size and weight, while also ensuring they can withstand environmental conditions and physical deformation.
Innovation Solution
A conformal wearable battery system featuring a matrix of battery cells arranged in a grid-like pattern, with a flexible printed circuit board assembly that can fold and include impact-absorbing members, and a sealed housing with conductive regions and contact components to provide electrical connections, ensuring a reliable seal against dust and water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional battery cells or larger battery cells are included to increase power storage capability, then power capacity is improved, but size and weight increase reducing mobility
Solution Approach 1:
The battery system is divided into multiple individual battery cells arranged in a matrix configuration. Each cell is separately housed and connected through a flexible circuit board, allowing the total power capacity to be distributed across multiple smaller units rather than one large cell, thus increasing capacity while managing weight distribution.
Solution Approach 2:
The battery cells are arranged in a compact matrix pattern within a housing structure, with cells nested closely together in an organized grid. This nesting arrangement maximizes the power capacity density within a constrained volume and weight budget, allowing more cells to be incorporated without proportionally increasing overall size.
2Quantity of substance
If additional battery cells or larger battery cells are included to increase power storage capability, then power capacity is improved, but size increases reducing mobility
Solution Approach 1:
The battery system is divided into multiple individual battery cells arranged in a matrix configuration. Each cell is separately housed and connected through a flexible circuit board, allowing the total power capacity to be distributed across multiple smaller units rather than one large cell, thus increasing capacity while managing volume distribution.
Solution Approach 2:
The battery cells are arranged in a compact matrix pattern within a housing structure, with cells nested closely together in an organized grid. This nesting arrangement maximizes the power capacity density within a constrained volume, allowing more cells to be incorporated without proportionally increasing overall size.
3Reliability
If a sealed housing is used to protect battery cells from environmental damage, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The sealed housing is divided into multiple separate compartments, each individually sealing a battery cell. This segmentation allows each cell to be sealed independently using standardized sealing processes, reducing the overall manufacturing complexity compared to sealing one large housing containing all cells, while still providing comprehensive environmental protection.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support for the battery cells, creates sealed environments to protect from moisture and dust, and houses the flexible circuit board connections. This multi-functionality reduces the need for additional separate components, simplifying manufacturing despite the sealed design requirements.
4Adaptability or versatility
If a flexible printed circuit board is used to connect battery cells in a foldable configuration, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The circuit board is designed as a flexible rather than rigid structure, allowing it to dynamically adapt to folding configurations and physical deformation. This flexibility enables the battery system to be bent and shaped without breaking electrical connections, providing adaptability to different wear configurations while the manufacturing precision requirements are managed through standardized flexible PCB fabrication processes.
Data Source
AI summary
A molded housing of a conformal wearable battery (CWB) encloses an electronic component and include an electrically conductive contact component embedded within an exterior wall to conduct electricity between an interior and an exterior of the casing. A flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) is enclosed in a cavity within the molded housing and includes attachment sections for a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. A visco-elastic shock-absorbing member installed between the upper and lower portion of the flexible PCBA when configured in a folded configuration. Each battery cell is joined to the flexible PCBA via a welding process. Each battery cell has a visco-elastic shock-absorbing member attached individually to each battery cell of the plurality of battery cells. When folded to fit within the cavity of the molded housing, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.