# US 2026/0094901 A1 · Freeform batteries > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2026/0094901 A1 - Document ID: US20260094901A1 - Status: Published application - Kind: A1 - Application number: 19/340,691 - Filed: 2025-09-25 - Published: 2026-04-02 - Earliest claimed: 2024-09-27 - Assignees: Apple Inc. - Applicants: Apple Inc. - Inventors: Karl A. Gazdowski; Premanand Ramadass; Stephen J. Wisler; Ibuki Kamei; Nathan L. Creado; Thomas A. Boehler; Yao Lu; Brian J. Haskins - Web page: https://patentgrep.com/patent/US20260094901A1 ## CPC - H01M 50/102: characterised by their shape or physical structure - H01M 10/0468: {Compression means for stacks of electrodes and separators} - H01M 10/049: {Processes for forming or storing electrodes in the battery container} - H01M 10/425: {Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00)} - H01M 50/103: prismatic or rectangular (H01M50/109, H01M50/11 take precedence) - H01M 50/119: Metals - H01M 50/169: by welding, brazing or soldering - H01M 50/284: with incorporated circuit boards, e.g. printed circuit boards [PCB] - H01M 50/296: characterised by terminals of battery packs (terminals of batteries H01M50/543) - H01M 2010/4271: {Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing} - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Batteries having convoluted, freeform shapes. These batteries can have curved and twisted surfaces that are freeform and do not have a constant radius or degree of rotation. A stack of battery layers can undergo a two-step heat press. The first heat press can be applied to the battery layers in a limited, low-stress region. This heat-press step can help to reduce delamination during a second heat-press step. In this second heat-press step, some or all of the battery layers can be pressed into a freeform shape and heat can be applied. The battery layers can then be placed in an enclosure. ## Claims ### Claim 1 A battery comprising: an enclosure housing the battery, the enclosure having a minor axis and a major axis and comprising a top can and a bottom can, the top can and bottom can forming a first side and a second side along the major axis, wherein the first side and the second side are nonparallel; a plurality of anodes coupled to a first terminal of the battery; a plurality of cathodes, each cathode between two of the plurality of anodes and coupled to a second terminal of the battery; and a plurality of separators, each around a corresponding cathode. ### Claim 2 (depends on 1) The battery of claim 1 wherein a top surface of the top can and a bottom surface of the bottom can are parallel. ### Claim 3 (depends on 1) The battery of claim 1 wherein a top surface of the top can and a bottom surface of the bottom can are nonparallel. ### Claim 4 (depends on 3) The battery of claim 3 wherein the first side and the second side along the major axis are curved. ### Claim 5 (canceled) ### Claim 6 (depends on 1) The battery of claim 1 wherein a top surface of the top can is curved along one or both of the major axis and the minor axis. ### Claim 7 (depends on 6) The battery of claim 6 wherein the top surface is twisted along one or both of the major axis and the minor axis. ### Claim 8 (canceled) ### Claim 9 (depends on 1) The battery of claim 1 further comprising: battery pack components coupled to the first terminal of the battery and the second terminal of the battery, the battery pack components having a first side and a second side, wherein the first side of the battery and the first side of the battery pack components follow a first curve and the second side of the battery and the second side of the battery pack components follow a second curve, the first curve different than the second curve. ### Claim 10 (depends on 9) The battery of claim 9 wherein the first side of the battery and the first side of the battery pack components are approximately contiguous and the second side of the battery and the second side of the battery pack components are approximately contiguous, wherein the first side of the battery pack components and the second side of the battery pack components are nonparallel. ### Claim 11 (depends on 10) The battery of claim 10 wherein the battery pack components comprise: a first terminal to connect to the first terminal of the battery; a second terminal to connect to the second terminal of the battery; and at least one of a protection circuit or a battery management unit. ### Claim 12 A battery comprising: a metal can housing the battery, the metal can comprising a top can having a top surface and a bottom can having a bottom surface, the metal can further comprising a first flange extending from a first end and a second flange extending from a second end; a plurality of anodes; a plurality of cathodes, each cathode between two of the plurality of anodes; a plurality of separators, each around a corresponding cathode; an electrical terminal on the first flange; and a fill hole to provide access to an interior of the metal can on the second flange. ### Claim 13 (depends on 12) The battery of claim 12 further comprising a fill plug to seal the fill hole. ### Claim 14 (depends on 13) The battery of claim 13 wherein the top surface is non-planar and the bottom surface is non-planer, and wherein the top surface and the bottom surface are parallel. ### Claim 15 (depends on 14) The battery of claim 14 wherein the battery has a minor axis and a major axis, and the metal can has a first side and a second side along the major axis, wherein the first side and the second side are curved and wherein the first side and the second side are parallel. ### Claim 16 (depends on 15) The battery of claim 15 wherein the top surface is curved along one or both of the major axis and the minor axis. ### Claim 17 (depends on 16) The battery of claim 16 wherein the top surface is twisted along one or both of the major axis and the minor axis. ### Claim 18 (depends on 12) The battery of claim 12 wherein the metal can comprises: a top portion having a recess and a first overhanging edge; and a bottom portion having a recess and a second overhanging edge, wherein the first overhanging edge and the second overhanging edge align to form the first flange and the second flange. ### Claim 19 A method of forming a battery, the method comprising: providing a first non-planar surface; providing a stack of components on the first non-planar surface; providing a second non-planar surface to the stack of components such that the stack of components is between the first non-planar surface and the second non-planar surface; applying heat to the stack of components; and applying pressure to the stack of components, wherein the stack of components comprises a plurality of anodes separated from each other by cathodes in a plurality of cathodes. ### Claim 20 (depends on 19) The method of claim 19 further comprising: placing the stack of components in a metal can, wherein the metal can is arranged to be sealed along a non-planar edge; and sealing the metal can along the non-planar edge with a laser, wherein the focal length of the laser is varied as the metal can is sealed. ### Claim 21 (depends on 20) The method of claim 20 further comprising, before providing the stack of components on the first non-planar surface: providing the stack of components on a first planar surface: applying a second planar surface to a portion of the stack of components; applying heat to the portion of the stack of components; and applying pressure to the portion of the stack of components. ### Claim 22 (depends on 19) The method of claim 19 wherein the first non-planar surface and the second non-planar surface are parallel when applying the heat and the pressure to the stack of components.