Flexible battery system for curved surface applications

Patent metadata

Field	Value
Publication number	US-2025364662-A1
Application number	US-202519219754-A
Country	US
Kind code	A1
Filing date	May 27, 2025
Priority date	May 24, 2024
Publication date	Nov 27, 2025
Grant date	—

Abstract

A flexible battery system for wearable and robotic applications comprises rigid or semi-rigid battery cells interconnected by flexible interconnection sections that enable conformability to curved contours while maintaining electrical connectivity. Each flexible interconnection section includes a flexible substrate with embedded conductive elements such as conductive traces, wires, or accordion-folded materials. The system includes a protective encapsulation layer and the battery cells may be arranged in linear, circular, or matrix configurations, including auxetic patterns for enhanced three-dimensional conformability.

First claim

1 . A flexible battery system for wearable applications comprising:
a plurality of rigid or semi-rigid battery cells arranged in a predetermined pattern; a plurality of flexible interconnection sections, each flexible interconnection section connecting adjacent battery cells in the predetermined pattern and providing electrical connectivity between the adjacent battery cells; and a protective encapsulation layer surrounding at least portions of the battery cells and the flexible interconnection sections; wherein the flexible interconnection sections enable the flexible battery system to conform to a body contour while maintaining electrical connectivity between the battery cells.

2 . The flexible battery system of claim 1 , wherein each flexible interconnection section comprises a flexible substrate with embedded conductive elements.

3 . The flexible battery system of claim 2 , wherein the flexible substrate comprises at least one of: polyimide film, a silicone elastomer, or a thermoplastic polyurethane.

4 . The flexible battery system of claim 2 , wherein the embedded conductive elements comprise at least one of: conductive traces, conductive wires, spring-like connectors, or accordion-folded conductive materials.

5 . The flexible battery system of claim 2 , wherein the flexible interconnection sections further incorporate strain relief features at junctions with the rigid or semi-rigid battery cells.

6 . The flexible battery system of claim 1 , wherein the plurality of battery cells are arranged in at least one of: a linear configuration, a circular configuration, or a matrix configuration.

7 . The flexible battery system of claim 6 , wherein the matrix configuration comprises an auxetic matrix pattern configured to provide three-dimensional conformability.

8 . The flexible battery system of claim 1 , wherein the rigid or semi-rigid battery cells comprise at least one of: lithium-ion cells, lithium-polymer cells, nickel-metal hydride cells, advanced alkaline cells, or solid-state battery cells.

9 . The flexible battery system of claim 1 , wherein the protective encapsulation layer comprises an inner moisture barrier, a middle impact protection layer, and an outer abrasion-resistant layer.

10 . The flexible battery system of claim 9 , wherein an outer surface of the protective encapsulation layer incorporates a foam or padded fabric.

11 . The flexible battery system of claim 1 , further comprising:
electrical interface connectors positioned at predetermined locations on the flexible battery system; and a thermistor wire integrated with the flexible battery system and traversing at least one of the flexible interconnection sections between adjacent battery cells for temperature monitoring and mechanical failure detection.

12 . An article of apparel comprising:
a garment structure configured to be worn on a body; a flexible battery system secured to the garment structure, the flexible battery system comprising:
a plurality of rigid or semi-rigid battery cells arranged in a predetermined pattern,
a plurality of flexible interconnection sections connecting adjacent battery cells and providing electrical connectivity between the adjacent battery cells, and
a protective encapsulation layer surrounding at least portions of the battery cells and the flexible interconnection sections; and
a garment attachment mechanism configured to secure the flexible battery system to the garment structure; and
wherein the flexible battery system conforms to body contours when the garment structure is worn.

13 . The article of apparel of claim 12 , wherein the garment attachment mechanism comprises at least one of: clips, magnetic connectors, hook-and-loop fasteners, slide-in channels, or elastic bands.

14 . The article of apparel of claim 12 , wherein the garment attachment mechanism is configured to removably secure the flexible battery system to the garment structure to facilitate battery charging without removing the garment structure.

15 . The article of apparel of claim 12 , further comprising at least one electronic component integrated with the garment structure and electrically connected to the flexible battery system.

16 . The article of apparel of claim 15 , wherein the at least one electronic component comprises at least one of: heating elements, lighting elements, sensors, communication devices, or computing devices.

17 . The article of apparel of claim 12 , wherein the flexible battery system is integrated into at least one of: a waistband, a cuff, a collar, a side panel, or a dedicated power pocket of the garment structure.

18 . The article of apparel of claim 12 , wherein the flexible battery system is arranged to distribute weight circumferentially around a portion of the body when the garment structure is worn.

19 . An athletic garment comprising:
a garment structure configured to be worn on a body during physical activity; a flexible battery system secured to the garment structure, the flexible battery system comprising:
a plurality of rigid or semi-rigid battery cells arranged in a predetermined pattern,
a plurality of flexible interconnection sections connecting adjacent battery cells and providing electrical connectivity between the adjacent battery cells,
a protective encapsulation layer that shields the battery cells and flexible interconnection sections from perspiration and mechanical stress,
thermal management features configured to maintain the battery cells within a predetermined temperature range during physical activity;
electronic components integrated with the athletic garment and powered by the flexible battery system; and
wherein the flexible battery system is configured to conform to body contours and accommodate body movement during physical activity.

20 . The athletic garment of claim 19 , wherein the electronic components comprise at least one of: performance monitoring sensors, biometric sensors, heating elements, cooling elements, lighting elements, or communication devices.

21 . The athletic garment of claim 19 , wherein the flexible battery system is arranged in a distribution pattern that distributes weight circumferentially around the body to reduce localized pressure points during athletic movement.

22 . The athletic garment of claim 19 , wherein the thermal management features comprise at least one of: heat-dissipating materials, insulation layers, or active cooling elements.

23 . The athletic garment of claim 19 , further comprising a battery management system configured to monitor cell health and optimize performance of the battery cells during physical activity.

Assignees

• Nike Inc

Inventors

• Gault Joseph B
• Lau Andrew C
• Martinez Jazzmin P
• Orand Austin J
• Raken Jan
• Weeks Daniel

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• A44D2203/00

  Fastening by use of magnets · CPC title

• A44B18/0003

  Fastener constructions (A44B18/0023, A44B18/0046 take precedence) · CPC title

• A43C11/1406

  Fastenings with toggle levers; Equipment therefor · CPC title

• H01M2220/30

  Batteries in portable systems, e.g. mobile phone, laptop · CPC title