Conformal Wearable Battery Layout for Higher Capacity and Mobility
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Solution Overview
Problem
There is a need in the mobile electrical power storage industry to increase power capacity while improving user safety and reducing the size and weight of portable battery systems, such as conformal wearable batteries, without compromising their mobility.
Innovation Solution
A conformal wearable battery system is designed with a matrix of battery cells arranged in a grid-like pattern, utilizing a flexible printed circuit board assembly that can fold to reduce mechanical stresses and incorporate impact-absorbing members, and a sealed housing with conductive components that provide reliable electrical connections and protection against environmental factors.
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, allowing the total power capacity to be distributed across several smaller units rather than one large cell. This segmentation enables flexible arrangement to achieve desired power capacity while controlling overall size and weight.
Solution Approach 2:
The battery cells are arranged in a compact matrix pattern within a housing structure, nesting multiple energy storage units in a space-efficient configuration. This allows maximum power capacity within minimum volume constraints.
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, allowing the total power capacity to be distributed across several smaller units rather than one large cell. This segmentation enables flexible arrangement to achieve desired power capacity while controlling overall size and weight.
Solution Approach 2:
The battery cells are arranged in a two-dimensional matrix pattern rather than a linear or single-dimensional configuration. This dimensional approach maximizes power density within a compact footprint, improving power capacity without proportionally increasing volume.
3Quantity of substance
If battery cells are arranged in a matrix configuration with conductive regions and contact components, then power capacity and electrical connection reliability are improved, but device complexity increases
Solution Approach 1:
Multiple functional elements are merged into integrated structures: the housing serves as both mechanical protection and structural support for the battery matrix; conductive regions are integrated directly with battery cell terminals; contact components combine electrical connection and mechanical retention functions. This merging reduces overall system complexity despite increased power capacity.
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides mechanical protection for battery cells, serves as a mounting structure for contact components, and defines the overall device form factor. This multi-functionality reduces the need for separate components, lowering complexity.
4Reliability
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 housing is designed as an integrated sealed structure that combines multiple functions: environmental protection, mechanical support for battery cells, and mounting structure for contact components. This single integrated component reduces manufacturing steps compared to assembling multiple separate protective and structural parts.
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides mechanical protection for battery cells, serves as a mounting structure for contact components, and defines the overall device form factor. This multi-functionality reduces the need for separate components, lowering complexity.
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 solution enhances power capacity, improves user safety, and reduces the size and weight of portable battery systems while maintaining mobility, with the flexible design and impact-absorbing features ensuring durability and reliability in various environmental conditions.
Implementation Method 1
a plurality of battery cells arranged in a grid-like pattern, where the plurality of battery cells have a positive terminal and a negative terminal to provide electricity through a transfer of electrons between the positive terminal and negative terminal
Implementation Method 2
a conductive region coupled to one or more of the positive terminal and the negative terminal, where the electricity is provided from one or more of the plurality of battery cells to the conductive region
Data Source
AI summary
Aspects described herein relate to a conformal wearable battery (CWB) and/or a system that includes plural battery cells. The CWB and/or system includes a flexible printed circuit board assembly (PCBA). The plurality of battery cells are arranged in a pattern on a same side of the flexible PCBA. One or more examples of the flexible PCBA include cutouts and electrical connection pads. A battery cell is connected to an electrical connection pad via electrically conductive elements, such as tabs. In one or more examples, the electrically conductive elements extend through the cutouts in the flexible PCBA. In other examples, the electrically conductive elements wrap around an edge of the flexible PCBA.