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WO2008023199A1 - Conformable battery packs - Google Patents

Conformable battery packs Download PDF

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Publication number
WO2008023199A1
WO2008023199A1 PCT/GB2007/050496 GB2007050496W WO2008023199A1 WO 2008023199 A1 WO2008023199 A1 WO 2008023199A1 GB 2007050496 W GB2007050496 W GB 2007050496W WO 2008023199 A1 WO2008023199 A1 WO 2008023199A1
Authority
WO
WIPO (PCT)
Prior art keywords
pack
power source
cells
source pack
cell
Prior art date
Application number
PCT/GB2007/050496
Other languages
French (fr)
Inventor
Peter Richard Barry
Jeremy Paul Frost
Jamie Thorburn
Original Assignee
Absl Power Solutions Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GB0616780A external-priority patent/GB0616780D0/en
Priority claimed from GB0710152A external-priority patent/GB0710152D0/en
Application filed by Absl Power Solutions Limited filed Critical Absl Power Solutions Limited
Publication of WO2008023199A1 publication Critical patent/WO2008023199A1/en

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M12/00—Hybrid cells; Manufacture thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1097—Fuel cells applied on a support, e.g. miniature fuel cells deposited on silica supports
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H1/00—Personal protection gear
    • F41H1/02—Armoured or projectile- or missile-resistant garments; Composite protection fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H1/00—Personal protection gear
    • F41H1/04—Protection helmets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H01M10/0436—Small-sized flat cells or batteries for portable equipment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/058—Construction or manufacture
    • H01M10/0585—Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M16/00—Structural combinations of different types of electrochemical generators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/14—Cells with non-aqueous electrolyte
    • H01M6/16—Cells with non-aqueous electrolyte with organic electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/40—Printed batteries, e.g. thin film batteries
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D1/00—Garments
    • A41D1/002—Garments adapted to accommodate electronic equipment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H01M10/0472—Vertically superposed cells with vertically disposed plates
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2250/00—Fuel cells for particular applications; Specific features of fuel cell system
    • H01M2250/30—Fuel cells in portable systems, e.g. mobile phone, laptop
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02B90/10—Applications of fuel cells in buildings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • This invention relates to thin electrical -power source packs that are body-mountable for human wearers .
  • the standard power source for a portable application is a rechargeable battery pack.
  • This is a metallic or plastic box, containing cells connected in series and/or parallel.
  • this box is rectangular and can only be mounted in certain positions on the body e.g. on the belt. This can often be inconvenient to the user, in activities like running and crawling.
  • the weight of the metal or plastic also reduces the energy density of the power source .
  • Lithium ion cells have the highest energy density of currently available rechargeable batteries. Initially, the cells were cylindrical. Subsequently, rectangular or prismatic cells in metal cans were produced, followed by soft pack cells in an aluminium laminate bag material. Applications like mobile phones demand a thin battery, and they can also be useful in devices like laptop computers .
  • This invention overcomes the inconvenience of the standard power sources by providing a pack that is relatively thin and that is sufficiently flexible to be body-conformable when worn and/or adaptable to conform to the contours of a non-planar worn object such as a rigid helmet or substantially inflexible body armour.
  • a non-planar worn object such as a rigid helmet or substantially inflexible body armour.
  • the invention provides a thin body-mountable electrical-power source pack for a human wearer that is sufficiently flexible to be body- conformable and contains one or more flat rigid lithium, metal/air or fuel cells or any combination of two or more thereof .
  • a thin body-mountable electrical-power source pack for a human wearer that is sufficiently flexible to be conformable to the contours of a rigid worn object, and contains one or more flat rigid lithium, metal/air or fuel cells or any combination of two or more thereof.
  • the pack may be in the form of an item or part of an item of clothing carrying the cell(s) and may, for example, be worn in the small of the back, between layers of clothing, on a helmet, on body armour, or in a pocket on the thigh.
  • the pack may be in the form of webbing carrying the cell(s) .
  • the pack may be rigid.
  • the pack is sufficiently flexible for it to be capable of conforming to the contours of the part of the human body, or of a fixed or rigid object, such as a helmet or body armour worn by a human being, where it is to be mounted.
  • body-conformable as applied to the pack means that the pack is capable of conforming to the contours of a rigid object that is worn on the human body, and/or is capable of conforming to the contours of part of the human body when in use. Suitable fabric materials are appropriate for this purpose, subject to their having sufficient durability for the wearer's needs.
  • suitable adhering means may be employed comprising fabric connectors, such as webbing, VeIcro and the like.
  • the maximum thickness of the pack is of the order of or not significantly greater than the thickness of clothing and/or webbing normally worn by military personnel.
  • the maximum thickness of the pack is no greater than 40 mm, such as no greater than 30 mm.
  • the cells may be from 2 to 20 mm thick, more preferably from 4 to 16 mm thick, more preferably 6 to 10 mm thick. In a particularly preferred embodiment the cells are 10 mm thick.
  • cell(s) of thickness 18 - 20 mm such as are known in the art may be used.
  • a pack including a plurality of rigid cells can be configured in a co-planar arrangement to have sufficient flexibility to be body-conformable. For example, the pack can bend along the gaps or axes between the cells. Depending on the thickness of the cells it may be possible to bend the cells slightly without breakage, and without deleterious effect on the power generating capacity of the cells. However, a rigid cell will typically break if it undergoes an extreme amount of bending, for example if it is folded in half.
  • the cell(s) may be primary or secondary.
  • electrochemical cell(s) examples include lithium cells such as rechargeable lithium cells, lithium ion cells, lithium ion polymer cells, lithium metal cells, lithium metal polymer cells and lithium primary cells, metal/air cells and fuel cells.
  • a thin, planar geometry can be advantageous for cells with air electrodes, to give a relatively large area for air ingress.
  • the cells may be connected in series or parallel in the pack .
  • the pack may contain two or more groups of cells where the cells in each group are connected in series and the groups of cells are connected in parallel.
  • the pack may contain one or more layers of cells. Depending on the capacity of the cells and the number of layers of cells in the pack, it is possible to assemble packs of the same size but with different stored energies .
  • the pack of the invention may contain two or more different types of cell, such as selected from rechargeable cells, fuel cells and super capacitors.
  • the power pack preferably forms a smart battery.
  • the smart battery also incorporates a battery health indicator which gives an indication of the maximum charge capacity as a proportion of the original charge capacity.
  • the power pack is compatible with a smart charger capable of level 3 charging.
  • a smart battery is a battery which complies with the Smart Battery Data Specification revision 1.1.
  • a smart charger is ' a charger which complies with Smart Battery Charger Specification revision 1.1.
  • each cell is protected against short circuits .
  • the cell is a lithium ion cell it is preferably protected against over-charging and against short circuit by an internal safety device, or for example by using a K2 cap cell protection device similar to that used in Li-ion D cells available from AGM Batteries Ltd.
  • the cells in each power pack are separate entities from one another.
  • the pack of the invention contains, within the pack an EMC interference abatement layer.
  • EMC interference abatement layer such as a metal mesh.
  • each cell or electronic circuit board can be encased by a separate mesh enclosure.
  • the EMC abatement layer is connected to a common ground typically through the connector that attaches to the equipment to be powered. Where the equipment is used in a stationary manner the equipment may have an earth connection.
  • the cells are encased in foam and the EMC abatement layer is a single layer round all the cells, typically just inside an outer waterproof layer.
  • the cells are typically encased in foam.
  • the foam is a flame retardant foam.
  • the foam on each side of the cells may be the same thickness or different thicknesses. In a preferred ' embodiment thicker foam is used on the side that is against the body in operation.
  • the foam is typically from 2 to 20 mm thick, preferably 4 to 15 mm thick, most preferably 10 mm thick.
  • all the cells are encased in a waterproof cover.
  • a waterproof cover also keeps the foam dry.
  • an indicator to display, directly or indirectly, information concerning the state of charge of the power source may be included.
  • Such indicators may be referred to as "fuel gauges" .
  • Such information may, for example, be relayed through a connector to be displayed visually upon activation by means of a switch or button.
  • the information may be conveyed to host equipment such as a laptop computer or mobile telephone to enable it to be accessed by the user.
  • the power source may include an indicator to display information concerning the state of health of a rechargeable battery or cell.
  • the indicator may display the maximum charge capacity of the battery as a proportion of the original maximum charge capacity.
  • the outer covering of the power pack has connectors attached to it which enable the pack to be mechanically connected to a harness, rucksack or other equipment .
  • the connectors are the universal clips as found on many rucksacks.
  • zips may be used to secure the power pack.
  • Figure 1 is a schematic plan view of a power- source pack in the form of a pouch, displaying electrochemical cells, and
  • Figure 2 is- a schematic side view corresponding to Figure 1.
  • FIG. 1 four thin planar electrochemical cells 1, 2, 3 and 4 are mounted on and in foam padding 5 which is contained within a protective flexible outer layer 6. Also provided within the foam padding 5 is an electrical connector 7.
  • Fold lines 9 are shown about which the power-source pack can be flexed to enable it to be inserted into the clothing of a user and conform to the contours of the body of a user.
  • FIG. 2 two of the planar cells 1 and 2 are shown mounted in the foam padding 5.
  • the protective outer layer 6 and the electrical connector 7 are also shown.
  • the protective outer layer 6 may, if necessary, be made of waterproof material which is preferably a breathable material such as Gortex TM.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)

Abstract

A thin, body-mountable electrical-power source pack for a human wearer that is sufficiently flexible to be body-conformable and contains one or more flat rigid lithium, metal/air or fuel cells or any combination of two or more thereof (1, 2, 3, 4).

Description

Conformable Battery Packs
FIELD OF THE INVENTION
This invention relates to thin electrical -power source packs that are body-mountable for human wearers .
BACKGROUND OF THE INVENTION
The standard power source for a portable application is a rechargeable battery pack. This is a metallic or plastic box, containing cells connected in series and/or parallel. Typically this box is rectangular and can only be mounted in certain positions on the body e.g. on the belt. This can often be inconvenient to the user, in activities like running and crawling. The weight of the metal or plastic also reduces the energy density of the power source .
Lithium ion cells have the highest energy density of currently available rechargeable batteries. Initially, the cells were cylindrical. Subsequently, rectangular or prismatic cells in metal cans were produced, followed by soft pack cells in an aluminium laminate bag material. Applications like mobile phones demand a thin battery, and they can also be useful in devices like laptop computers .
SUMMARY OF THE INVENTION
This invention overcomes the inconvenience of the standard power sources by providing a pack that is relatively thin and that is sufficiently flexible to be body-conformable when worn and/or adaptable to conform to the contours of a non-planar worn object such as a rigid helmet or substantially inflexible body armour. Thus, with a flexible body-conformable pack of the invention, as the body contours alter with movement, so the power- source pack will move and conform to whatever shape the body takes up.
Thus, in one aspect the invention provides a thin body-mountable electrical-power source pack for a human wearer that is sufficiently flexible to be body- conformable and contains one or more flat rigid lithium, metal/air or fuel cells or any combination of two or more thereof .
In another aspect of the invention there is provided a thin body-mountable electrical-power source pack for a human wearer that is sufficiently flexible to be conformable to the contours of a rigid worn object, and contains one or more flat rigid lithium, metal/air or fuel cells or any combination of two or more thereof.
The pack may be in the form of an item or part of an item of clothing carrying the cell(s) and may, for example, be worn in the small of the back, between layers of clothing, on a helmet, on body armour, or in a pocket on the thigh.
Also, the pack may be in the form of webbing carrying the cell(s) .
The pack may be rigid. Preferably, the pack is sufficiently flexible for it to be capable of conforming to the contours of the part of the human body, or of a fixed or rigid object, such as a helmet or body armour worn by a human being, where it is to be mounted. Thus, the term "body-conformable" as applied to the pack means that the pack is capable of conforming to the contours of a rigid object that is worn on the human body, and/or is capable of conforming to the contours of part of the human body when in use. Suitable fabric materials are appropriate for this purpose, subject to their having sufficient durability for the wearer's needs. Where the pack is to be mounted on a rigid object such as a helmet suitable adhering means may be employed comprising fabric connectors, such as webbing, VeIcro and the like.
By "thin" is meant that the maximum thickness of the pack is of the order of or not significantly greater than the thickness of clothing and/or webbing normally worn by military personnel. For example, the maximum thickness of the pack is no greater than 40 mm, such as no greater than 30 mm.
For the pack to be "thin", the cell(s) themselves must be thinner than the pack. The cells may be from 2 to 20 mm thick, more preferably from 4 to 16 mm thick, more preferably 6 to 10 mm thick. In a particularly preferred embodiment the cells are 10 mm thick. For example, cell(s) of thickness 18 - 20 mm such as are known in the art may be used.
The cell(s) themselves are rigid or substantially inflexible. A pack including a plurality of rigid cells can be configured in a co-planar arrangement to have sufficient flexibility to be body-conformable. For example, the pack can bend along the gaps or axes between the cells. Depending on the thickness of the cells it may be possible to bend the cells slightly without breakage, and without deleterious effect on the power generating capacity of the cells. However, a rigid cell will typically break if it undergoes an extreme amount of bending, for example if it is folded in half.
The cell(s) may be primary or secondary. As examples of electrochemical cell(s) that may be used in the invention, there may be mentioned lithium cells such as rechargeable lithium cells, lithium ion cells, lithium ion polymer cells, lithium metal cells, lithium metal polymer cells and lithium primary cells, metal/air cells and fuel cells. A thin, planar geometry can be advantageous for cells with air electrodes, to give a relatively large area for air ingress.
The cells may be connected in series or parallel in the pack . In one embodiment the pack may contain two or more groups of cells where the cells in each group are connected in series and the groups of cells are connected in parallel.
The pack may contain one or more layers of cells. Depending on the capacity of the cells and the number of layers of cells in the pack, it is possible to assemble packs of the same size but with different stored energies .
The pack of the invention may contain two or more different types of cell, such as selected from rechargeable cells, fuel cells and super capacitors.
Where lithium ion or other cells that can form a smart battery are used then the power pack preferably forms a smart battery. In a particularly preferred embodiment the smart battery also incorporates a battery health indicator which gives an indication of the maximum charge capacity as a proportion of the original charge capacity. In a preferred embodiment the power pack is compatible with a smart charger capable of level 3 charging. A smart battery is a battery which complies with the Smart Battery Data Specification revision 1.1. A smart charger is' a charger which complies with Smart Battery Charger Specification revision 1.1.
In a preferred embodiment each cell is protected against short circuits . Where the cell is a lithium ion cell it is preferably protected against over-charging and against short circuit by an internal safety device, or for example by using a K2 cap cell protection device similar to that used in Li-ion D cells available from AGM Batteries Ltd. In one embodiment there is also a further cell protection circuit for the power pack as a whole.
The cells in each power pack are separate entities from one another.
Advantageously, the pack of the invention contains, within the pack an EMC interference abatement layer. Typically all the cells are encased in a single EMC interference abatement layer such as a metal mesh. However, each cell or electronic circuit board can be encased by a separate mesh enclosure. The EMC abatement layer is connected to a common ground typically through the connector that attaches to the equipment to be powered. Where the equipment is used in a stationary manner the equipment may have an earth connection. In one embodiment the cells are encased in foam and the EMC abatement layer is a single layer round all the cells, typically just inside an outer waterproof layer.
The cells are typically encased in foam. In a preferred embodiment the foam is a flame retardant foam. The foam on each side of the cells may be the same thickness or different thicknesses. In a preferred ' embodiment thicker foam is used on the side that is against the body in operation. The foam is typically from 2 to 20 mm thick, preferably 4 to 15 mm thick, most preferably 10 mm thick.
In a preferred embodiment all the cells are encased in a waterproof cover. Thus, although the power pack as a whole may get wet, no water will contact the cells. This waterproof cover also keeps the foam dry.
Optionally and desirably, an indicator to display, directly or indirectly, information concerning the state of charge of the power source may be included. Such indicators may be referred to as "fuel gauges" . Such information may, for example, be relayed through a connector to be displayed visually upon activation by means of a switch or button. Alternatively, the information may be conveyed to host equipment such as a laptop computer or mobile telephone to enable it to be accessed by the user.
In a further embodiment, the power source may include an indicator to display information concerning the state of health of a rechargeable battery or cell. Thus the indicator may display the maximum charge capacity of the battery as a proportion of the original maximum charge capacity. In a preferred embodiment the outer covering of the power pack has connectors attached to it which enable the pack to be mechanically connected to a harness, rucksack or other equipment . Typically the connectors are the universal clips as found on many rucksacks.
Alternatively, zips may be used to secure the power pack.
It is an object of the present invention to provide a power pack for powering equipment such as radios, portable computers or powered tools.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE
The invention will now be particularly described, by way of example only, with reference to the accompanying drawings in which:
Figure 1 is a schematic plan view of a power- source pack in the form of a pouch, displaying electrochemical cells, and
Figure 2 is- a schematic side view corresponding to Figure 1.
Referring to Figure 1, four thin planar electrochemical cells 1, 2, 3 and 4 are mounted on and in foam padding 5 which is contained within a protective flexible outer layer 6. Also provided within the foam padding 5 is an electrical connector 7.
Fold lines 9 are shown about which the power-source pack can be flexed to enable it to be inserted into the clothing of a user and conform to the contours of the body of a user.
Referring to Figure 2, two of the planar cells 1 and 2 are shown mounted in the foam padding 5. The protective outer layer 6 and the electrical connector 7 are also shown.
Both Figures 1 and 2 show an EMC interference abatement layer 8 as dashed lines.
The protective outer layer 6 may, if necessary, be made of waterproof material which is preferably a breathable material such as Gortex ™.

Claims

Claims
1. A thin, body-mountable electrical-power source pack for a human wearer that is sufficiently flexible to be body-conformable and contains one or more flat rigid lithium, metal/air or fuel cells or any combination of two or more thereof .
2. A power source pack as claimed in claim 1 in the form of an item or part of an item of clothing carrying the cells.
3. A power source pack as claimed in claim 1 in the form of webbing carrying the cell(s) .
4. A power source pack according to claim 1 wherein the pack is conformable to the contours of a rigid worn non- planar object.
5. A power source pack according to claim 4 wherein the pack is conformable to the contours of a helmet.
6. A power source pack according to claim 4 wherein the pack is conformable to the contours of body armour.
7. A power source pack as claimed in any one of claims 1 to 6 that has a thickness that is no greater than 40 mm.
8. A power source pack as claimed in claim 7 that has a thickness that is no greater than 30 mm.
9. A power source pack as claimed in any of claims 1 to 8 containing within the pack an electromagnetic interference abatement layer.
10. A power source pack as claimed in any of claims 1 to 9 containing, within the pack, cell(s) of a thickness from 2 mm to 20 mm.
11. A power source pack as claimed in claim 10 containing within the pack cell(s) of a thickness from 4 to 16 mm.
12. A power source pack as claimed in claim 10 containing within the pack cell(s) of a thickness of 10 mm.
13. A power source pack as claimed in any of claims 1 to 12 including an indicator to provide information concerning the state of charge of the power source .
14. Flexible clothing comprising a power source pack as claimed in any of claims 1 to 13.
15. Rigid non-planar clothing comprising a power source pack as claimed in any of claims 1 to 13.
16. Rigid clothing as claimed in claim 15 which is a helmet .
17. Rigid clothing as claimed in claim 15 which is body armour .
PCT/GB2007/050496 2006-08-24 2007-08-17 Conformable battery packs WO2008023199A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB0616780A GB0616780D0 (en) 2006-08-24 2006-08-24 Battery packs
GB0616780.3 2006-08-24
GB0710152.0 2007-05-29
GB0710152A GB0710152D0 (en) 2007-05-29 2007-05-29 Battery packs

Publications (1)

Publication Number Publication Date
WO2008023199A1 true WO2008023199A1 (en) 2008-02-28

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US8927137B2 (en) 2012-05-01 2015-01-06 Microsun Technologies Llc Fail safe damage resistant battery matrix
US9812680B2 (en) 2012-08-30 2017-11-07 Apple Inc. Low Z-fold battery seal
US9136510B2 (en) 2012-11-26 2015-09-15 Apple Inc. Sealing and folding battery packs
US9593969B2 (en) 2013-12-27 2017-03-14 Apple Inc. Concealed electrical connectors
US9479007B1 (en) 2014-02-21 2016-10-25 Apple Inc. Induction charging system
US10629886B2 (en) 2014-03-06 2020-04-21 Apple Inc. Battery pack system
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US9917335B2 (en) 2014-08-28 2018-03-13 Apple Inc. Methods for determining and controlling battery expansion
US10847846B2 (en) 2014-08-28 2020-11-24 Apple Inc. Methods for determining and controlling battery expansion
WO2016059370A1 (en) * 2014-10-14 2016-04-21 Intelligent Energy Limited Fuel cell powered portable electronic devices
GB2531286A (en) * 2014-10-14 2016-04-20 Intelligent Energy Ltd Fuel cell powered portable electronic devices
WO2018007606A1 (en) 2016-07-07 2018-01-11 Commissariat A L'energie Atomique Et Aux Energies Alternatives High-capacity metal-ion electrochemical accumulator the flexibility of which allows great conformability
US10637017B2 (en) 2016-09-23 2020-04-28 Apple Inc. Flexible battery structure
US12075904B2 (en) 2019-04-17 2024-09-03 Apple Inc. Battery connection system for a wirelessly locatable tag
US11316227B2 (en) 2020-09-30 2022-04-26 Inventus Power, Inc. Conformal wearable battery
US11064604B1 (en) 2020-09-30 2021-07-13 Inventus Power, Inc. Flexible circuit board for a conformal wearable battery
US12114426B2 (en) 2020-09-30 2024-10-08 Inventus Power, Inc. Conformal wearable battery and system
US11251497B1 (en) 2020-09-30 2022-02-15 Inventus Power, Inc. Conformal wearable battery
US11081755B1 (en) 2020-09-30 2021-08-03 Inventus Power, Inc. Housing for a conformal wearable battery
US11349174B2 (en) 2020-09-30 2022-05-31 Inventus Power, Inc. Flexible battery matrix for a conformal wearable battery
US12087956B2 (en) 2020-09-30 2024-09-10 Inventus Power, Inc. Conformal wearable battery
US10950913B1 (en) 2020-09-30 2021-03-16 Inventus Power, Inc. Impact absorbing member for a conformal wearable battery
US11477885B2 (en) 2020-09-30 2022-10-18 Inventus Power, Inc. Redundant trace fuse for a conformal wearable battery
US10980116B1 (en) 2020-09-30 2021-04-13 Inventus Power, Inc. Flexible battery matrix for a conformal wearable battery
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USD937222S1 (en) 2020-10-30 2021-11-30 Inventus Power, Inc. Electrical contact
USD939433S1 (en) 2020-10-30 2021-12-28 Inventus Power, Inc. Battery
US11394077B1 (en) 2021-03-15 2022-07-19 Inventus Power, Inc. Conformal wearable battery
US11581607B1 (en) 2021-09-30 2023-02-14 Inventus Power, Inc. Thermal management for a conformal wearable battery

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