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Free Form Battery solutions are made possible by Lithylene, a technology and trademark owned by Koninklijke Philips Electronics NV. ID Enabler Corporation, a licensee of Lithylene technology, provides Free Form Battery solutions for a wide range of important applications in the communications, IT, and consumer electronics sectors.

Particularly focusing on power solutions for identification and authentication, ID Enabler Corporation is a leader in micro power applications.

Technology

Lithylene technology enables precision battery construction using rivet assembly. This is a powerful technology that can be used to make free form factor batteries without sacrificing performance. Batteries produced through rivet assembly can be made to follow the contours of the host device product and be placed along the edges of the device. Device designers enthusiastically adopt Free Form Battery solutions when space and shape are of paramount consideration in device design.

Rivet assembly leverages the conventional idea of securing layered materials together using rivets. In battery assembly, electrodes (cathode and anode) are placed on top of each other with separators in between (Fig. 1). Each of these electrodes has already been punched with small holes (Fig. 2, Fig. 3). Holes on the separator are made after alignment with hot needles.

A thin sheet of rivet polymer is then applied to the top and bottom of the electrode stack and, under specific heating and pressure conditions, the polymer will penetrate each of the holes (Fig. 4, Fig. 5). Once cooled, the polymer hardens, keeping active materials in contact and providing a very stable battery structure (Fig. 6, Fig 7). The rivet polymer ensures electrical contact between electrode layers, and thereby eliminates the need for a conventional metal can. As the rivet polymer is not chemically involved with redox reactions, thus it will not suffer any detrimental side effects after repeated charge and discharge cycles (Fig. 8).

A video demonstration is provided for better understanding the Lithylene process, and how this unique process makes Free Form Batteries possible.



Application

Historically, the battery has been considered a “black box” in product design. Free Form Batteries made using Lithylene technology will revolutionize the way designers and consumers view battery solutions. Applications of Free Form Batteries range from consumer electronics to specialty goods. Free Form Batteries will make use of most, if not all, available space within the host device, resulting in longer product lifetime and better performance.

Presently Free Form Batteries are limited to rechargeable Li-ion electro-chemistry. Because of the use of standard materials, Free Form Batteries, regardless of shape and dimension, always meet state-of-the-art requirements. Typical cycle life and discharging curves compared against counterparts in standard configuration are depicted for general reference.

More performance information available in trial order page.

Ultra Slim BatteryApplication

Proved DesignUltra Slim

One time password (OTP) as a source of the second authentication has been recognized an essential tool to prevent banking fraud. An increasing number of financial institutions have installed OTP systems to assure the highest standard of transaction security. Ultra slim batteries provide the power source to enable OTP solutions in wallet applications, allowing credit and bank cards to receive OTP upon transaction.

More than two billion RFID tags have been sold to date. Out of the figure more than 400 million RFID tags have embedded batteries thus providing the ability to emit signals. These devices are dubbed "active RFID". When active RFID tags appear in card form, ultra slim batteries are used as the power source. Such batteries require thickness of under 0.5 mm, too thin to employ conventional battery assembly.

Above are some proven applications for Free Form Batteries. Now imagine what you can do with this new dimension in design freedom.

Tape Shape BatteryApplication

Proved DesignTape

The Free Form Battery in tape shape has many applications. It fits in device surface rather than in device volume, making device design more flexible when adding power source into equation. Not necessarily thin and slim, tape shape Free Form Battery can be thick to meet various requirement in applications.

This is a further application of Free Form Batteries. Now imagine what you can do with this new dimension in design freedom.

Ring Shape BatteryApplication

Proved DesignRing Shape

Extending tape shape Free Form Battery in the long axis will result in Free Form Battery in ring shape. Such battery is considered useful in many medical devices such as patient tracker on the wrist. It has been successfully applied to power a special device for erectile dysfunction in clinic treatment. Not necessarily thin and slim, ring shape Free Form Battery can be thick to meet various requirement in applications.

This is a further application of Free Form Batteries. Now imagine what you can do with this new dimension in design freedom.

Curved Shape BatteryApplication

Proved DesignCurved Shape

Extending tape shape Free Form Battery in the short axis will result in a curved shape Free Form Battery. This form factor receives the most inquiries because it addresses obvious requirements in various electronic gadgets where designers wish to fill the inner space with the maximum energy content.

This is a further application of Free Form Batteries. Now imagine what you can do with this new dimension in design freedom.

Semi-curved Shape BatteryApplication

Proved DesignSemi-curved Shape

The curved shape Free Form Battery can easily be made semi-curved by keeping one side flat. This is also welcome in numerous electronic gadgets where maximum energy content is a key design criterion.

This is a further application of Free Form Batteries. Now imagine what you can do with this new dimension in design freedom.

Arbitrary Shape BatteryApplication

Proved DesignArbitrary Shape

Unique shapes are also available for unusual applications. For example, a Free Form Battery in diamond square shape has been placed on the wings of unmanned surveillance aircraft. The device is dispatched to remote or dangerous zones to take pictures, which are subsequently sent back to the control center wirelessly.

This is a further application of the Free Form Battery. Now imagine what you can do with this new dimension of design freedom.

Application

Your Design

While providing enormous flexibility to the device designer, the Free Form Battery does have design constraints of which the designer should be aware. Firstly, the molding facility cannot provide two-way bending such as seen in a “horse saddle” shape. Secondly, the bending arc must be kept smaller than 150 degrees, bending radius greater than 15 mm, and the battery thickness less than 5 mm. Please refer to the sample chart where bending arc is 115 degrees (smaller than 150 degrees), bending radius is 25 mm (greater than 15 mm) and battery thickness is 3 mm (less than 5 mm).


Sample Chart

If your design meets the basic requirements above, you are more than welcome to place a trial order to see how the Free Form Battery could benefit your business.

Trial Order

Trial Order

Presently Free Form Battery is limited to rechargeable Li-ion electro-chemistry. Because of the use of standard materials, the Free Form Battery, regardless of shape and dimension, always meets state-of-the-art requirements.

If you are not familiar with rechargeable Li-ion system (which is exactly the same as those used in common devices and gadgets such as laptop computers and cellular phones), please refer to following charts depicting discharging curves at different discharge rates, and different temperatures, and please also see the charging curves by constant current in the first stage and constant voltage in the second stage.

Discharge Curve vs. Rate Discharge Curve vs. Temp. CC-CV Charging Algorithm
Trial Order

Capacity Estimation

Battery capacity is a result of battery volume. For any given design, it is very easy to estimate available capacity using volumetric energy density, which is a figure between 280 and 320 Wh/Liter for the selected electro-chemistry.

To make a quick estimation, please carefully calculate in liters the volume of your design. The capacity you should expect will vary between [(280 x Volume) / 3.7 Volt] and [(320 x Volume) / 3.7 Volt]. The capacity you derive from the equation will be expressed in ampere-hour (Ah) .

Exact capacity is determined by effective use of space after battery assembly. You can place sample order to know better the true capacity of your design.

Trial Order

Online Order Form

In the preliminary stage all we need is your battery design in an engineering drawing with legends provided in metric units. We do not need to know how and where you will use your battery. Before sending your design, please again review the design constraints described in Application / Your Design.

Due to the large number of inquires we receive, we do not sign non-disclosure agreements (NDA) upon receipt of the engineering drawing. NDA on an as-needed basis can be provided in the next stage of sample development. You can rest assured that we are committed to the highest standards of intellectual property protection, and your valuable IP is safe .

Free Form Battery samples can be made at non-recurring engineering (NRE) costs. We are delighted to assist in estimating the feasibility and cost of your designs.

Please send an email to inquiry@freeformbattery.com with your engineering drawing attached. We will process your inquiry within 7 days of receipt.

Contact Us

Free Form Battery Business Division
ID Enabler Corporation
Room 209, 2/F, No. 99 Tun-Hua S. Road, Sec. 2
Taipei, 106, TAIWAN

Fax -- +886 2 8192 6940

Email -- inquiry@freeformbattery.com