A fabric-based origami structure battery and a method of manufacturing the same

Abstract

The application relates to the technical field of fabric-based batteries, in particular to a fabric-based origami structure battery and a preparation method thereof. The preparation method comprises the following steps: integrally preparing a cathode and a diaphragm on the surface of a polyester fiber fabric; using a wax lamination method, transferring molten paraffin to the surface of the fabric except the cathode area and the diaphragm area by using a hollow template to form a hydrophobic barrier; cutting zinc foil into square blocks with the same size as the cathode, and pasting the zinc foil on the fabric substrate in the anode area marked in advance through an ultrathin double-sided adhesive tape; preparing a crease line between adjacent functional areas on the fabric at a preset distance from the electrode edge; adding NaCl aqueous solution to the diaphragm area, drying after fully soaking the diaphragm, making NaCl precipitate in the form of solid crystals and remain in the fabric fiber pores, obtaining the diaphragm after pre-deposition treatment, and preparing the fabric-based origami structure battery; and the fabric-based battery preparation can realize on-demand construction and programmable topology reconfiguration.

Description

Technical Field

[0001] This invention relates to the field of fabric-based battery technology, and in particular to a fabric-based origami structure battery and its preparation method. Background Technology

[0002] The rapid development of flexible electronic devices and wearable technologies has created an urgent need for energy systems to be more flexible, lightweight, and safe. Traditional rigid batteries struggle to adapt to the complex curves and dynamic deformations of the human body; therefore, developing batteries with good mechanical flexibility has become a key challenge in this field. Among the many strategies for constructing flexible batteries, using fabrics as a substrate is considered a highly promising technological approach due to its natural compatibility with everyday clothing, excellent mechanical flexibility, and potential for scalable fabrication.

[0003] Currently, fabric-based batteries are mainly divided into two categories based on their structural morphology. One type is one-dimensional fiber batteries, which are further woven into flexible power supply fabrics by coating or wrapping electrode materials onto the fiber surface. The other type is two-dimensional planar batteries, which directly print or deposit active materials on the fabric surface to form sheet-like power supply units. Although these two types of batteries have made significant progress in single-point performance, they still face fundamental limitations at the system integration level: one-dimensional fiber batteries require complex weaving processes to form a usable power system, the reliability of the connection points between fibers is difficult to guarantee during the weaving process, and the series and parallel structures are fixed after weaving and cannot be flexibly adjusted. Although the fabrication process of two-dimensional planar batteries is relatively simple, the integration of multiple battery units still relies on external wire connections, which not only occupies additional planar area but also makes it difficult to achieve high-density series and parallel combinations in a limited space. The essence of these problems is that existing research on fabric-based batteries is still within the design framework of two-dimensional space. Neither the weaving of fibers nor the planar arrangement has broken through the limitations of two-dimensional morphology on system integration.

[0004] Origami, as an advanced method of three-dimensional structure programming and manufacturing, can guide two-dimensional materials to undergo controllable and reversible folding and unfolding through pre-designed crease patterns, thereby dynamically constructing a rich variety of three-dimensional functional structures. In recent years, origami structures have shown significant potential in the fields of energy storage and batteries. For example, by introducing specific crease patterns, batteries can be made stretchable and flexible; high energy density of devices within a limited space can be achieved through folding transformations; and the capacity limitations of planar devices can be overcome by using three-dimensional stacking. However, existing origami energy storage devices are mostly based on paper, thin films, or planar flexible substrates, and research focuses mainly on the deformability or volume compression of the devices. Existing fabric-based batteries are mostly limited to the fiber or planar device level, and a power system that uses fabric as a functional substrate, starts with two-dimensional patterned layout, and achieves on-demand battery construction, topological reconstruction, and high-density integration through folding has not yet been formed.

[0005] Therefore, developing a fabric-based battery fabrication method that enables on-demand construction and programmable topology reconfiguration is of significant research importance and application value. Summary of the Invention

[0006] The purpose of this invention is to provide a fabric-based origami structure battery and its preparation method, which enables fabric-based battery preparation with on-demand construction and programmable topology reconfiguration.

[0007] To achieve the above objectives, in a first aspect, the present invention provides a method for fabricating a paper-folding structure battery, comprising:

[0008] Using screen printing, conductive carbon paste is used as the printing material on the surface of polyester fiber fabric. A carbon cathode layer is formed in the cathode area by scraping. The printing process parameters are controlled so that the penetration depth of the conductive carbon paste reaches 30%-70% of the total thickness of the polyester fiber fabric. The other half of the polyester fiber fabric thickness that is not wetted by the conductive carbon paste serves as the diaphragm layer. After printing, the polyester fiber fabric is dried to solidify the carbon paste, thus completing the integrated preparation of the cathode and diaphragm.

[0009] A wax lamination method is used to transfer molten paraffin to the fabric surface, excluding the cathode area and the diaphragm area, using a perforated template to form a hydrophobic barrier with a water contact angle ≥120°.

[0010] The zinc foil is cut into square blocks of the same size as the cathode and then attached to the pre-marked anode area on the fabric substrate using ultra-thin double-sided tape.

[0011] Pre-fabricated crease lines are made between adjacent functional areas on the fabric at a predetermined distance from the electrode edge, with the crease depth controlled to be 10%-50% of the total fabric thickness;

[0012] NaCl aqueous solution was added dropwise to the membrane area to fully wet the entire membrane and then dried so that NaCl precipitated in solid crystal form and remained in the pores of the fabric fibers, thus obtaining a pre-deposited membrane and fabric-based origami structure battery.

[0013] An activation liquid is added dropwise to the pre-deposited membrane area. The liquid is drawn into the membrane through capillary action and dissolves the NaCl solid, generating an electrolyte solution in situ. The battery is then activated by folding the fabric along the creases to power electronic devices.

[0014] The process involves screen printing, where conductive carbon paste is used as the printing material on the surface of a polyester fiber fabric. A carbon cathode layer is formed in the cathode area using a scraping method. The printing process parameters are controlled to ensure the conductive carbon paste penetrates to 30%-70% of the total thickness of the polyester fiber fabric. The remaining half of the polyester fiber fabric thickness, not wetted by the conductive carbon paste, serves as the separator layer. After printing, the polyester fiber fabric is dried to solidify the carbon paste, thus completing the integrated preparation of the cathode and separator.

[0015] The screen printing uses a 300-mesh screen printing plate, with a squeegee pressure of 0.01-0.1 MPa, a squeegee angle of 60°-80°, and a printing speed of 50-150 mm / s. The printing method involves first performing three reciprocating strokes in the horizontal direction, then rotating the squeegee 90° and performing three reciprocating strokes in the vertical direction. The drying conditions are: drying at 90 ℃ for 30 min to solidify the carbon paste.

[0016] In the step of using a wax lamination method to transfer molten paraffin to the fabric surface (excluding the cathode and diaphragm areas) using a perforated template to form a hydrophobic barrier with a water contact angle ≥120°, the specific process of the wax lamination method is as follows:

[0017] Solid paraffin wax is heated to 120 ℃ to completely melt it. A perforated template made of A4 paper is immersed in the molten paraffin wax for 2-3 seconds. After cooling, the template containing paraffin wax is attached to the surface of the fabric. Then, it is hot-pressed at 120 ℃ and 0.1-0.5 MPa for 5 seconds. After hot pressing, the template is removed to obtain the hydrophobic barrier.

[0018] In the step of cutting zinc foil into square blocks of the same size as the cathode and attaching the zinc foil to the pre-marked anode area on the fabric substrate using ultra-thin double-sided tape,

[0019] The zinc foil has a thickness of 0.02 mm, and the ultra-thin double-sided tape has a thickness of 0.01 mm.

[0020] In the step of pre-faking crease lines between adjacent functional areas on the fabric at a predetermined distance from the electrode edge, with the crease depth controlled to be 10%-50% of the total fabric thickness,...

[0021] The creases are prefabricated by manually bending them back and forth 1-5 times, or by using indentation, hot pressing, or molding.

[0022] In one step, NaCl aqueous solution is added dropwise to the membrane region to fully wet the entire membrane, followed by drying. This allows NaCl to precipitate as solid crystals and remain in the pores of the fabric fibers, resulting in a pre-deposited membrane. This process is crucial for fabricating a paper-folding structure battery based on fabric.

[0023] The NaCl aqueous solution is a 2 mol / L NaCl aqueous solution, and the amount added is 40 μL; the drying conditions are: drying in an environment of 20-30 ℃ and 30%-60% RH for 6-24 hours.

[0024] In one step, an activation liquid is dripped into the pre-deposited membrane region. The liquid is drawn into the membrane through capillary action and dissolves the NaCl solid, generating an electrolyte solution in situ. The battery is then activated by folding the fabric along the creases to power the electronic device.

[0025] The activating liquid is any one of deionized water, sweat, milk, or juice.

[0026] Secondly, the present invention also provides a fabric-based origami structure battery, comprising a polyester fiber fabric, a separator layer, a cathode layer, a hydrophobic barrier, and an anode; the cathode layer is attached to the surface of the polyester fiber fabric and partially embedded in the thickness direction; the separator layer is disposed on the thickness portion of the polyester fiber fabric directly below the cathode layer and is integrally connected to the cathode layer; the hydrophobic barrier is disposed on the surface of the polyester fiber fabric in the area other than the cathode layer and the separator layer, adjacent to the cathode layer and the separator layer but not overlapping them; the anode is adhered to the surface of the polyester fiber fabric.

[0027] This invention discloses a fabric-based origami-structured battery and its fabrication method. Using fabric as a substrate, the battery functional units (cathode, anode, separator, and wires) are pre-patterned on a two-dimensional plane, and a controllable transformation from a planar precursor to a three-dimensional battery system is achieved through folding. A fabric-based battery is constructed using screen-printed carbon as the cathode, the fabric body as the separator, zinc foil as the anode, and screen-printed silver as the wires. In the unfolded state, the functional areas are separated, and the device is in an unconnected state. After the separator is wetted by liquid and folded, the cathode, separator, and anode come into contact, and the battery is constructed on demand and outputs electrical energy, thus achieving physical decoupling between the storage state and the working state. Based on the pre-programmed layout and folding path design in the two-dimensional plane, this system can not only form a single cell but also stably construct series, parallel, and hybrid structures of multiple cells, achieving adjustable voltage, current, and power output. This system can also be further integrated into everyday objects with natural opening / closing behavior, wearable clothing, and portable emergency carriers, directly converting the liquid acquisition and structural folding process into battery activation and connection steps. This fabric-based origami structure battery provides a novel power solution for wearable electronics, smart fabrics, and portable energy fields, offering flexibility, programmability, high-efficiency integration, and the potential for large-scale manufacturing. This invention enables the fabric-based battery fabrication with on-demand construction and programmable topology reconfiguration. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0029] Figure 1 This is a manufacturing process diagram for a single cell of a fabric-based origami structure battery.

[0030] Figure 2 This is a performance characterization and parameter optimization data chart of a fabric-based origami structure single-cell cell.

[0031] Figure 3 These are characterization diagrams of the water evaporation, electrolyte absorption, and discharge performance of a single fabric-based origami battery under different conditions.

[0032] Figure 4 These are structural design diagrams and performance characterization data diagrams of series and parallel battery packs for fabric-based origami batteries.

[0033] Figure 5 This is a comparison of the power density of a series-parallel system built using origami techniques and a system built using conventional wiring and stacking.

[0034] Figure 6 It shows a schematic diagram and performance test data of a hybrid structure of parallel-to-serial and serial-to-parallel.

[0035] Figure 7 This is a design, packaging, and power supply demonstration diagram of a hybrid fabric-based origami battery pack for different loads.

[0036] Figure 8 This is a schematic diagram illustrating the structural design and performance characterization of the same fabric-based battery precursor, which achieves different electrical connections through different folding methods.

[0037] Figure 9 It is a schematic diagram and performance characterization data diagram of a series / parallel battery pack stacked together.

[0038] Figure 10 This is a characterization data of pre-deposited NaCl on a fabric separator and a schematic diagram of the suitability test of fabric-based origami batteries in a real wearable environment.

[0039] Figure 11 This demonstrates the power supply capability of fabric-based origami batteries in outdoor carrying scenarios.

[0040] Figure 12 This is a schematic diagram illustrating the coupling ability test between a fabric-based origami structure battery and a real object shape.

[0041] Figure 13 This is a schematic diagram illustrating the large-area fabrication of batteries using a screen printing machine to power light boards.

[0042] Figure 14 These are SEM images of the cross-section of the Zn sheet and the fabric separator, the surface of the screen-printed carbon, and the cross-section of the screen-printed carbon and the fabric separator when the origami structure battery is folded and in use.

[0043] Figure 15 These are cross-sectional SEM images and EDS spectra of the Zn sheet and fabric diaphragm.

[0044] Figure 16 It consists of cross-sectional SEM images of the fabric and the screen-printed silver layer, and EDS images of the silver element distribution on the fabric fibers.

[0045] Figure 17 It consists of surface SEM images of the fabric and the screen-printed silver layer, and EDS images of the silver element distribution on the fabric fibers.

[0046] Figure 18 This is a schematic diagram of a contact angle measuring instrument characterizing the hydrophilicity of a fabric diaphragm.

[0047] Figure 19 This is a schematic diagram of a contact angle measuring instrument characterizing the hydrophobicity of the hydrophobic region constructed by wax lamination.

[0048] Figure 20 This is a flowchart of a fabric-based origami structure battery fabrication method according to the present invention.

[0049] Figure 21 This is a schematic diagram of a fabric-based origami structure battery according to the present invention.

[0050] Figure 22 This is a schematic diagram of the structure of a fabric-based origami structure battery according to the present invention from another perspective.

[0051] 1-Polyester fiber fabric, 2-Separator layer, 3-Cathode layer, 4-Hydrophobic barrier, 5-Anode. Detailed Implementation

[0052] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0053] Firstly, please refer to Figures 1-22 This invention provides a method for fabricating a paper-folding structure battery, comprising:

[0054] S1 uses screen printing. Conductive carbon paste is used as the printing material on the surface of polyester fiber fabric 1. A carbon cathode layer 3 is formed in the cathode area by scraping. The printing process parameters are controlled so that the penetration depth of the conductive carbon paste reaches 30%-70% of the total thickness of the polyester fiber fabric 1. The other half of the thickness of the polyester fiber fabric 1 that is not wetted by the conductive carbon paste serves as the diaphragm layer 2. After printing, the polyester fiber fabric 1 is dried to solidify the carbon paste, thus completing the integrated preparation of the cathode and the diaphragm.

[0055] In this step, the screen printing uses a 300-mesh screen printing plate, the squeegee pressure is 0.01-0.1 MPa, the squeegee angle is 60°-80°, and the printing speed is 50-150 mm / s. The printing method is to first perform three back-and-forth printings in the horizontal direction, and then rotate the squeegee 90° and perform three back-and-forth printings in the vertical direction. The drying conditions are: drying at 90 ℃ for 30 min to solidify the carbon paste.

[0056] In this embodiment of the invention, the zinc foil thickness is 0.02mm-0.08mm, the fabric is made of 100% polyester fiber, the double-sided adhesive thickness is 0.01mm, and sodium chloride (NaCl, 99.5%) is used. A carbon cathode is prepared on the surface of the purchased fabric using screen printing technology. First, a 300-mesh screen printing stencil is selected. The stencil has pre-prepared opening patterns consistent with the cathode area size (1.4 cm × 1.4 cm). A clean polyester fiber fabric 1 is laid flat on the printing table, ensuring it is smooth and wrinkle-free. The stencil is then placed on top of the fabric, and its position is adjusted to precisely align the opening patterns with the pre-marked cathode area on the fabric, with the alignment deviation controlled to ≤1 mm. Place an appropriate amount of conductive carbon paste at one end of the screen. Control the squeegee pressure to be 0.01-0.1 MPa, the squeegee angle to be 60°-80°, and the printing speed to be 50-150 mm / s. Perform a test print first to observe the transfer and penetration depth of the carbon paste on the fabric surface. Fine-tune the squeegee pressure and speed accordingly until the desired penetration effect is achieved. After determining the parameters, operate the squeegee to perform three back-and-forth printings in the horizontal direction. Each back-and-forth is defined as the squeegee moving from one end of the screen to the other and then returning to the starting position. After completing the horizontal printing, rotate the squeegee 90° and then perform three back-and-forth printings in the vertical direction. This cross-printing method ensures that the carbon paste is evenly distributed in the cathode area and fully fills the opening of the screen. During the printing process, the carbon paste partially penetrates the fabric in the thickness direction under the pressure of the squeegee. By controlling the number of printing passes and the squeegee pressure, the carbon paste penetration depth reaches 30%-70% of the total fabric thickness. Preferably, the cathode layer 3 occupies about 50% of the fabric thickness, and the other half of the fabric not soaked in carbon paste is reserved as the separator layer 2 of the subsequent battery. After printing, the fabric is transferred to an oven and dried at 90 °C for 30 min to fully solidify the carbon paste, thus completing the integrated preparation of the cathode and separator.

[0057] S2 uses a wax lamination method to transfer molten paraffin to the fabric surface except for the cathode area and the diaphragm area using a perforated template, forming a hydrophobic barrier with a water contact angle ≥120°.

[0058] In this step, the specific process of the wax lamination method is as follows: solid paraffin wax is heated to 120 ℃ to completely melt it, a perforated template made of A4 paper is immersed in the molten paraffin wax for 2-3 seconds, after being taken out and cooled, the template containing paraffin wax is attached to the surface of the fabric, and then placed under 120 ℃ and 0.1-0.5 MPa pressure for 5 seconds for hot pressing. After hot pressing is completed, the template is removed to obtain the hydrophobic barrier 4.

[0059] In this embodiment of the invention, to achieve directional transport and constraint of the electrolyte on the fabric substrate, a hydrophobic barrier 4 is constructed in locations other than the electrode and diaphragm regions using a wax lamination method. First, computer-aided design software is used to draw the pattern of the required hydrophobic area, and ordinary A4 paper is cut into corresponding perforated templates. Solid paraffin wax is heated to 120 °C until it is completely melted. The A4 paper template is then immersed in the molten paraffin wax for 2-3 seconds, removed, and allowed to cool slightly, allowing a suitable amount of paraffin wax to adhere to the template surface. The paraffin-laden template is then attached to the surface of the fabric on which the carbon cathode has been prepared, ensuring that the template accurately covers the area requiring hydrophobic treatment, with the alignment error between the template and the fabric controlled to ≤1 mm. Subsequently, the template-fabric assembly is placed in a hot press preheated to 120 °C, and a pressure of 0.1-0.5 MPa is applied for 5 seconds. During the hot press process, the paraffin wax in the template melts upon heating and transfers to the underlying fabric fibers, spreading uniformly along the fabric thickness direction under pressure. After hot pressing, the template is removed, and the area on the fabric covered by the template forms a hydrophobic barrier 4; the uncovered cathode area and its corresponding diaphragm area retain the original hydrophilicity of the fabric. The hydrophobic area constructed by this process has a water contact angle ≥120°, and deionized water droplets added to this area will not penetrate the hydrophobic barrier 4 within 1 hour.

[0060] S3 cuts the zinc foil into square blocks of the same size as the cathode and attaches the zinc foil to the pre-marked anode 5 area on the fabric substrate using ultra-thin double-sided tape;

[0061] In this step, the zinc foil has a thickness of 0.02 mm, and the ultra-thin double-sided tape has a thickness of 0.01 mm.

[0062] In this embodiment of the invention, a zinc foil with a thickness of 0.02 mm is cut into small square pieces of the same size as the cathode. Then, using ultra-thin double-sided tape (0.01 mm), the zinc foil is pasted onto the pre-marked anode 5 area on the fabric substrate, ensuring that the zinc foil adheres tightly to the fabric without obvious wrinkles.

[0063] S4 pre-fabricates crease lines between adjacent functional areas on the fabric at a preset distance from the electrode edge, with the crease depth controlled to be 10%-50% of the total fabric thickness;

[0064] In this step, the crease prefabrication method is to manually bend the crease back and forth 1-5 times, or to complete it by indentation, hot pressing or molding.

[0065] In this embodiment of the invention, before activating the battery, crease lines need to be pre-made on the fabric to ensure precise folding. The geometric position of the crease lines is set between adjacent functional areas and about 3 mm away from the edge of the electrode. The pre-making method of the creases is as follows: along the predetermined fold line, manually bend back and forth 1-5 times to form a controllable structural weakening of the fabric fibers at that point, and control the crease depth to 10%-50% of the fabric thickness; as an equivalent alternative, pre-making can also be completed by mechanical methods such as creasing, hot pressing or molding.

[0066] S5 adds NaCl aqueous solution to the membrane area, fully wets the entire membrane and then dries it, so that NaCl precipitates in solid crystal form and remains in the pores of the fabric fibers, and obtains the pre-deposited membrane, thus producing a fabric-based origami structure battery.

[0067] In this step, the NaCl aqueous solution is a 2 mol / L NaCl aqueous solution, and the amount added is 40 μL; the drying conditions are: drying in an environment of 20-30 ℃ and 30%-60% RH for 6-24 hours.

[0068] In this embodiment of the invention, after the crease pre-fabrication is completed, the fabric with the prepared electrodes and hydrophobic regions is placed on the operating table. 40 μL of a 500 mM NaCl aqueous solution is accurately measured using a pipette and added dropwise to the separator area, ensuring the solution fully wets the entire separator. Furthermore, to expand the battery's environmental adaptability, the fabric separator undergoes NaCl pre-deposition treatment, enabling it to be activated by various liquids. First, a 2 mol / L NaCl aqueous solution is prepared as the pre-deposition solution. 40 μL of this solution is accurately measured using a pipette and added dropwise to the separator area, ensuring the solution fully wets the entire separator. Subsequently, the device is placed in an environment with a temperature of 20-30 °C and a relative humidity of 30%-60% RH for natural drying for 6-24 hours. After the moisture has completely evaporated, NaCl precipitates uniformly in solid crystal form and remains in the pores of the fabric fibers. The uniformity of NaCl distribution in the fiber can be indirectly verified by the following method: randomly select several pre-deposited devices and activate them, then test their instantaneous open-circuit voltage and constant current discharge performance. If the performance of each device is highly consistent, it indicates that the NaCl distribution is uniform. At this point, the battery pre-deposited with solid NaCl is complete and can be stored in a sealed environment in a dry place.

[0069] S6 adds activation liquid to the pre-deposited membrane area. The liquid is drawn into the membrane through capillary action and dissolves NaCl solid, generating an electrolyte solution in situ. The battery is then activated by folding the fabric along the creases to power electronic devices.

[0070] In this step, the activating liquid is any one of deionized water, sweat, milk, or juice.

[0071] In this embodiment of the invention, the fabric is folded along the pre-fabricated crease lines to precisely align the cathode region with the anode 5 region, with the folding positioning error controlled to ≤2 mm. At this point, the portion of the fabric not impregnated with carbon paste serves as the separator layer 2, naturally located between the cathode and anode 5, thus activating the battery and enabling it to operate. Depending on different experimental requirements, a single battery cell can be constructed through a single fold, or series, parallel, and hybrid battery packs can be constructed through multiple folds. The storage shelf life of the device of this invention is at least 1-12 months. During use, only a certain amount of activating liquid (such as deionized water, sweat, milk, juice, etc.) needs to be added to the pre-deposited separator region. The liquid is drawn into the separator through capillary action and dissolves the NaCl solid, generating an electrolyte solution in situ. Folding the fabric along the creases then activates the battery, directly powering the electronic device.

[0072] The microstructure of the battery was characterized using field emission scanning electron microscopy. Hydrophilicity was measured using a contact angle meter by adding 2 μL of water to the device surface. Open-circuit voltage, Nyquist plot, and LSV measurements were performed using an electrochemical workstation. Constant-current discharge testing was conducted using a LAND battery testing system. Repeated torsion testing (torsion angle: 180°; frequency: 0.1 Hz) was performed by fixing the battery on a flexibility tester. See details in the reference section. Figures 9-14 , Figure 9 The figures are as follows: a. SEM image of the cross-section of Zn sheet and fabric membrane when folded for use; b. SEM image of the surface of screen-printed carbon; c. SEM image of the cross-section of screen-printed carbon and fabric membrane.

[0073] To better understand this invention, specific application examples and experimental results are provided below to illustrate it.

[0074] refer to Figure 1 , Figure 1 This is a manufacturing process diagram for a single cell of a fabric-based origami structure battery.

[0075] The fabric was cut into a predetermined shape and size, and a carbon cathode was prepared on the surface by screen printing. Scanning electron microscopy (SEM) showed that the cured carbon paste tightly coated the surface of the fabric fibers, forming a continuous and uniform conductive layer with an interfacial resistance of approximately 46 Ω. Since the carbon paste did not completely penetrate the fabric, the unwetted half of the fabric acted as a membrane layer 2, exhibiting good hydrophilicity. Figure 18 The cross-sectional SEM image clearly shows the layered structure of both. This integrated electrode / diaphragm design based on the fabric body fully utilizes the inherent thickness and porous structure of the fabric, simplifying the manufacturing process and reducing costs while meeting ion transport requirements. Except for the carbon electrode and diaphragm, other areas are laminated with wax to form a hydrophobic barrier, exhibiting good hydrophobicity. Figure 19 This effectively constrains the distribution range of the electrolyte and limits the ion transport channels, laying the foundation for subsequent independent operation of multiple units and complex circuit integration. Finally, ultra-thin double-sided tape is used to fix the zinc foil in a specific position, ensuring close contact with the fabric fibers. Figure 15 ), to complete the electrode arrangement on a two-dimensional plane ( Figure 1 In this embodiment, the cathode, anode 5, and separator regions are all arranged with equal dimensions to ensure precise alignment during folding, thereby maximizing the effective contact area of ​​the electrodes. The battery's operation relies on the structural transformation caused by folding. In the unfolded state, the cathode, anode 5, and separator are spatially separated, and the device is in an unconnected state, thus avoiding continuous energy consumption in the connected state. Electrolyte is added to the separator, and after complete folding along predefined creases, these functional layers are brought into close contact by clamping, forming a complete electrochemical cell and triggering the oxidation reaction (Zn-2e). - →Zn 2+ ) and reduction reaction (O2 + 2H2O + 4e) - →4OH - It provides an open-circuit voltage of 1-1.2V. This mechanically triggered "on-off" mechanism decouples the storage state from the operating state, avoiding the continuous consumption of traditional primary batteries in the connected state, and enabling on-demand build and on-demand startup.

[0076] refer to Figure 2 , Figure 2 This is a graph showing the performance characterization and parameter optimization data of a single cell unit with a fabric-based origami structure. Figure 2 The figures are as follows: (a) Maximum power output of batteries with different cathode structures; (b) Polarization curves and power output curves of batteries activated by different concentrations of NaCl solution; (c) Corresponding Nyquist plots; (d) 0.1 mA constant current discharge curves with different zinc foil thicknesses; (e) Discharge behavior under different external pressures; (f) Comparison of continuous discharge and intermittent discharge curves.

[0077] In Zn-air battery systems, the oxygen reduction reaction (ORR) at the cathode is often a key step limiting battery performance, and its reaction kinetics largely depend on the effective active area of ​​the electrode. By adjusting the distribution ratio of carbon paste in the cathode region (50%, 75%, and 100%), three different cathode structures were tested. Figure 2(a) It can be observed that the maximum output power of the battery increases significantly with the increase of the coverage area, with the 100% covered cathode exhibiting the highest power output. This is mainly attributed to the fact that the larger active area provides more oxygen reduction reaction sites, thereby improving ORR kinetics. Therefore, a fully covered cathode was used as the standard structure in subsequent experiments. To study the effect of ion concentration on the output of a single cell, NaCl aqueous solution was selected as a representative neutral activation medium. This system is not only simple in composition and easy to control, but also similar to the main inorganic salt components in sweat, so it can also serve as a basic model for subsequent wearable scenario research. As the NaCl concentration increases from 100 mM to 500 mM, the discharge voltage plateau and output power of the battery increase significantly, but when the concentration is further increased to 700-900 mM, the performance improvement tends to plateau ( Figure 2 (b) indicates that 500 mM is close to the optimal ionic conductivity conditions. Electrochemical impedance spectroscopy (EIS) results further show that high-concentration electrolytes can reduce charge transfer impedance, but the improvement in impedance is limited beyond a certain concentration. Figure 2 c). Therefore, 500 mM was selected as the standard working concentration in subsequent experiments to balance conductivity and material stability. Under the same electrolyte volume conditions, stable discharge was achieved with zinc foils of different thicknesses (0.02-0.08 mm). The discharge voltage plateau and discharge duration of each battery were basically the same, and the output performance of the battery was not limited by the thickness of the zinc anode. Figure 2 d), this result is consistent with the theory, and the thickness of the zinc anode 5 mainly affects the theoretical capacity of the battery. Therefore, a zinc foil thickness of 0.02 mm was selected in subsequent experiments to balance the flexibility and folding adaptability of the device. The external pressure on the folded battery was controlled by the clamp and monitored by a thin-film pressure sensor. The results showed that the battery's discharge voltage increased slightly with increasing pressure, and tended to stabilize after exceeding 10 kPa. Figure 2 (e) indicates that the pressure was sufficient to achieve tight contact between the electrodes and the separator and reach the lowest contact resistance; further increasing the pressure had no significant impact on battery performance. In subsequent experiments, we ensured that each cell was fully compressed to ensure stable output, and no longer precisely controlled the pressure to a specific value.

[0078] By comparing continuous discharge and intermittent discharge behaviors, and simulating scenarios of single-use and intermittent battery use in real-world applications, the impact of the folding-unfolding on / off mechanism on battery life was verified. Figure 2f). In a high-humidity, low-temperature environment, equal volumes of 40 μL electrolyte were added to both the control and experimental groups. The control group was folded and continuously discharged until the voltage dropped below a certain value (0.58 V), at which point discharge ceased. The experimental group was discharged intermittently for 40 minutes, then unfolded and left to stand for 20 minutes until the discharge voltage also dropped below 0.58 V. The cumulative discharge capacity of the control and experimental groups was then calculated. The results showed that the discharge capacity of the experimental group was significantly higher than that of the control group. This is because the folding-unfolding process is not only a form-switching process but also constitutes a physical switch for the battery: when unfolded, the device is in an unconnected state, which helps reduce ineffective consumption in the connected state, thereby inhibiting zinc electrode self-corrosion, improving the utilization rate of active materials, and extending the effective working time.

[0079] refer to Figure 3 , Figure 3 Figures characterizing the water evaporation, electrolyte absorption, and discharge performance of a single fabric-based origami battery under different conditions; Figure 3 The figures are as follows: (a) Schematic diagram of the water evaporation process of a single cell; (b) Maximum electrolyte absorption capacity of the separator; (c) Constant current discharge curves of the single cell when 10 μL of electrolyte is added at different positions on the separator for activation; (d) Discharge curves of the single cell after adding 10-40 μL and 500 mM NaCl solutions under environmental conditions; Effects of ambient temperature (e), wind speed (f), and relative humidity (g) on ​​the discharge behavior of the single cell after adding 40 μL and 500 mM NaCl solutions. (eg) The inset shows the corresponding water evaporation curve; (h) Discharge curves of the single cell after 500-2000 torsions in the unfolded state; (i) Discharge voltage response of the single cell under periodic mechanical vibration. All discharge tests were conducted under a constant current of 0.1 mA.

[0080] Evaporation of water in the electrolyte is unavoidable under real-world conditions. Figure 3 a), which directly affects the ion transport and discharge behavior of the battery. The maximum electrolyte carrying capacity of the separator in a single fabric-based origami structure battery, measured through wicking experiments, is approximately 40 μL ( Figure 3 b). The discharge curves obtained by adding 10 μL of electrolyte from different positions on the diaphragm were basically consistent. Figure 3 c), which aligns with the 51:1 alignment of the cathode, separator, and anode. This allows the electrolyte to participate in the reaction at any location within the folded region, effectively establishing ion transport channels and driving electrochemical reactions locally. Battery performance is not sensitive to the initial liquid distribution. Under the same environmental conditions, as the electrolyte volume increases from 10-40 μL, the initial discharge voltage gradually increases, and the battery discharge time is significantly prolonged. Figure 3d) indicates that a higher liquid volume helps maintain the reaction process and delays performance degradation due to evaporation. Figure 3 d). The effects of ambient temperature, wind speed, and humidity on the performance of batteries containing 40 μL of electrolyte are as follows: Figure 3 As shown in the example, as the temperature increases from 15℃ to 45℃, the evaporation rate of the electrolyte increases sharply, causing the discharge time to shorten from 14.4 h to 0.7 h. Within 0–2.4 ms... -1 Within the specified wind speed range, electrolyte evaporation accelerates with increasing wind speed, reducing the discharge time from 5.3 h to 1 h. When relative humidity changes from 25% to 80%, the evaporation process is suppressed, increasing the discharge time from 2.8 h to 5.3 h. Overall, higher temperatures and wind speeds accelerate moisture loss, thus shortening battery operating time, while higher humidity helps suppress evaporation and maintain more stable output.

[0081] Under mechanical disturbance, the battery still maintains stable operation. After 500-2000 twists, its initial discharge voltage and plateau did not show significant decay. Compared to the battery that had not undergone twisting, the discharge time of the battery that had been twisted 2000 times was reduced by only 0.3 hours. Figure 3 h); When periodic shaking is applied during discharge, the battery output voltage remains stable overall, with only slight fluctuations occurring at the moment of disturbance (h). Figure 3 i). The shaking caused a brief voltage drop ( Figure 3 However, after the disturbance ended, the system was able to quickly recover to its original discharge plateau, and no significant cumulative decay was observed. This indicates that the mechanical disturbance mainly has a transient effect on the electrode contact or local electrolyte distribution, without damaging the overall reaction structure and ion transport channels of the battery, thus ensuring the stable operation of the system under dynamic conditions.

[0082] refer to Figure 4 , Figure 4 These are structural design diagrams and performance characterization data diagrams for series and parallel battery packs of fabric-based origami batteries. Figure 4 The figures are as follows: (a) Two-dimensional layout of series and parallel battery arrays, assembly process based on folding and corresponding circuit diagrams; (b) The second four-unit series structure, its folding method and equivalent circuit diagram; (c, d) Polarization curves and power output curves of series and parallel battery arrays with different numbers of units; (e) Performance comparison of two four-unit folded series structures and wire-connected series structures.

[0083] After clarifying the working mechanism, environmental adaptability, and mechanical stability of a single cell, this study expands the research object from "cell" to "system" to investigate whether origami design can transform the electrode layout in a two-dimensional plane into a programmable circuit topology for multiple cells. To this end, silver paste is screen-printed in specific areas of the fabric as a conductive interconnect layer to establish pre-defined connections between adjacent cells after folding. SEM and EDS characterization show that the cured silver paste forms stable conductive connection points on the fabric surface, achieving conduction across both sides through the fabric thickness. Figure 16 and Figure 17 Its surface resistance and through resistance at the connection points are both approximately 0.3 Ω, providing a stable, low-resistance electrical connection for multi-unit folding assembly. For example... Figure 4 As shown in Figure a, by adjusting the arrangement of battery cells in a two-dimensional plane and the position of the silver paste interconnects, the same design strategy can generate two types of folded battery packs: series and parallel. It should be noted that although the interconnect structure is pre-patterned on the two-dimensional plane, the system remains open-circuited in the unfolded state because the cathode layer 3, anode 5, and separator layer 2 have not yet made contact. Only after folding, as each cell completes its individual cell construction, does the pre-fabricated silver interconnect layer automatically connect adjacent cells according to the predetermined topology, thus enabling the on-demand construction of multi-cell systems. Therefore, Figure 4 The folding strategy shown in diagram a not only achieves physical "on-off" control of a single cell but also transforms the pre-programmed connections in the two-dimensional plane into the actual output topology of a multi-cell battery pack. Electrochemical tests show that the interconnections pre-written into the two-dimensional fabric plane can be stably transformed into preset series and parallel outputs after folding. For the series configuration, as the number of series cells increases from 1 to 4, the open-circuit voltage and impedance of the battery pack increase synchronously, the polarization curve shifts upward along the voltage axis, and the maximum output power increases accordingly. Figure 4 c), consistent with the typical response of a series connection. In contrast, parallel devices maintain an operating voltage range similar to that of a single cell, but exhibit a wider output current range and higher power output ( Figure 4 d), demonstrating the characteristics of parallel current increase. Therefore, folding in this system is not only a morphological transformation process, but also a step in converting a two-dimensional design into a system-level electrical function.

[0084] To further examine the dependence of this integration strategy on specific folding paths, a second four-unit tandem configuration was designed. Figure 4 b), and combine it with configuration 1 ( Figure 4 a) Compared with the traditional series connection method, the polarization curves and power curves of the three are basically the same. Figure 4(e) No significant performance differences were observed. This indicates that, with the same number of cells and equivalent interconnect topology, the output of the battery pack is mainly determined by the performance of individual cells and the overall circuit structure, and is not sensitive to the specific folding path. More importantly, the interconnection efficiency achieved by folding is comparable to that of external wire connections, indicating that this strategy can achieve reliable multi-cell integration while reducing additional components. Therefore, folding in this work is not simply a deformation method, but a core step in achieving circuit construction and system integration.

[0085] refer to Figure 5 , Figure 5 (f) A comparison of the power density of the series-parallel system constructed using origami technology with that of the conventional wiring and stacking system; (g) A comparison of the power density of folded integration and three-dimensional stacking integration; (h) Corresponding photographs.

[0086] In addition to electrical output, folded integration significantly restructures the spatial organization of devices. Compared to traditional three-dimensional stacked integration, folded integration exhibits higher volumetric power density. Figure 5 a); Compared with two-dimensional routing integration that requires reserving a large planar wiring area, its area power density advantage is more prominent ( Figure 5 b). The actual photos verify this: the four battery cells, each with a side length of 2 cm when folded, occupy approximately 16 cm² if arranged in a flat surface. 2 If conventional stacking is used, a 12-layer battery stack can be formed, with a total fabric thickness of approximately 0.146 mm × 12; however, after folding and integration, the device can be compressed into a compact 2 × 2 cm module, forming a 9-layer stacked structure. Figure 5 c). These results demonstrate that the origami strategy not only endows fabric batteries with programmable connectivity but also unifies two-dimensional planar design with three-dimensional high-density integration in the same device, providing a foundation for subsequent hybrid structure construction and output regulation for different loads.

[0087] refer to Figure 6 , Figure 6 This is a schematic diagram and performance test data graph of the parallel-then-serial and hybrid serial-then-parallel structures. Figure 6 The figures in the table are as follows: (a) Schematic diagram of the hybrid structure of parallel-to-series (2S2P) and series-to-parallel (2P2S) and its scalability; (b) Polarization curves and power output curves of 2S2P and 2P2S battery packs; (c) Nyquist plots of single cell, dual-cell series structure and 2S2P structure; (d) Nyquist plots of single cell, dual-cell parallel structure and 2P2S structure.

[0088] After confirming that the folding strategy can construct reliable series and parallel topologies, this invention further extends the research focus from "basic connection units" to "application-oriented complex circuit systems," examining whether origami design can achieve the controllable construction of hybrid battery packs through pre-programmed layouts in a two-dimensional plane. To this end, two typical four-unit hybrid configurations were designed: series-to-parallel (2S2P) and parallel-to-series (2P2S). Figure 6 a). It is worth emphasizing that these two configurations, when fully folded, have identical macroscopic geometry and space occupancy, but exhibit drastically different behaviors in their internal electrical networks. Polarization and power curves show that both achieve synergistic voltage and current boosts (a). Figure 6 b). Although their macroscopic output performance is similar, the impedance evolution processes of the systems are different due to the different internal connection sequences. Electrochemical impedance spectroscopy results show that the total impedance of the system increases significantly after connecting two units in series in a single cell. Further construction of a 2S2P structure on this basis results in a decrease in impedance. Figure 6 c). This change conforms to the basic principle that series connection increases equivalent impedance and parallel connection decreases equivalent resistance, indicating that the units have been effectively interconnected according to the preset topology after folding. In contrast, in the parallel-then-series configuration, the two single cells are first connected in parallel, thereby reducing the system impedance. After further constructing the 2P2S structure, the total impedance increases again. Figure 6 d). The above results demonstrate that the origami strategy can not only achieve single series or parallel outputs, but also further realize the pre-programmed construction of hybrid topologies. Its electrical response is consistent with the laws of classical circuits, indicating that the connection design in the two-dimensional plane can be stably transformed into the preset hybrid output after folding.

[0089] It is important to note that the 2S2P and 2P2S configurations presented in this invention are merely the smallest conceptual units for verifying hybrid logic. Since their connection relationships are predefined by a two-dimensional planar layout, this system has a structural basis for further expanding the array topology. By increasing the number of patterned units along specific directions on a two-dimensional fabric plane, the hybrid structure can be expanded laterally or vertically. For example, the 2S2P structure can be expanded into 2S3P along the parallel direction to further increase the total current output; it can also be expanded into 3S2P along the series direction to increase the overall operating voltage. Following this logic, the device can, in principle, be extended to a more general mSnP (m series n parallel) array configuration. Based on this two-dimensional programmable layout, the hybrid structure can continue to expand in different directions, thereby achieving coordinated regulation of output voltage and current while maintaining folded integration characteristics, and providing adjustable power supply solutions for different load requirements.

[0090] refer to Figure 7 , Figure 7 This is a design, packaging, and power supply demonstration diagram of a hybrid fabric-based origami battery pack for different loads. Figure 7 The images in the middle are: (a) the unfolded structure of the 2S16P battery pack, the folding and box-type packaging process after three rounds of manual crimping, and a real photo of the device driving the small fan; (b) the unfolded structure of the 4P5S battery pack, and a real photo of the device after folding, slot-type packaging, and driving the laser pointer.

[0091] After completing the electrical verification of the hybrid topology, two types of hybrid battery packs and their corresponding packaging methods were further designed to match the current and voltage requirements of different loads. For current-driven loads, a 2S16P hybrid battery pack was constructed to increase the total output current while maintaining a certain output voltage. Figure 7 a). Due to the numerous parallel units arranged laterally in the plane, this configuration exhibits a distinct elongated shape when unfolded. After longitudinal folding along a predetermined fold line, the battery pack's internal structure is connected according to a pre-defined topology. Because its lateral dimensions are still relatively large, hindering compact storage, further lateral folding is performed to compress the overall volume, ultimately fitting it into a plastic box of approximately 4 × 3 × 2 cm. The lid provides continuous external pressure after closure, ensuring a tight fit between all contact interfaces. Notably, after three manual rubbing sessions before use, the battery pack can still stably drive a small fan with a rated current of approximately 20 mA, indicating that the system has good tolerance to non-ideal mechanical disturbances. For voltage-driven loads, a 4P5S hybrid battery pack was designed to increase the overall output voltage while maintaining low branch impedance. Figure 7 (b) After the device is folded longitudinally along the preset fold line, its internal connections can also be constructed according to the preset topology. Due to the small lateral dimensions, the folded structure is already quite compact, so there is no need for further lateral folding. The device can be directly inserted into a slot of approximately 9 × 3 × 0.4 cm, where the slot provides external pressure and fixes the structure, enabling stable power supply to a laser pointer with a rated voltage of 2 V and a power of 10 mW. It should be noted that the difference between the box and the slot mainly comes from the device size and shape, rather than the working mechanism itself; as long as sufficient external pressure can be provided, both types of battery packs can be fixed and used using either the box or the slot in principle. These results show that folding first transforms the two-dimensional pre-programmed layout into actual circuit connections, while subsequent packaging achieves device compression, volume reduction, and portable storage. Therefore, the origami structure not only determines the connection topology of the battery pack but also provides corresponding space compression and packaging adaptation strategies for different array sizes and load requirements.

[0092] refer to Figure 8 , Figure 8 This is a schematic diagram of the structural design and performance characterization of the same fabric-based battery precursor, which achieves different electrical interconnection results through different folding methods. Figure 8The figures in the figure are: a schematic diagram (a) showing how the same planar device can form a parallel battery pack by folding with type 1 and a series battery pack by folding with type 2, and the corresponding physical photos (b), polarization curve and power output curve (c), and Nyquist plot (d).

[0093] In this system, folding not only transforms planar devices into three-dimensional structures but also determines the final contact relationships between functional areas. Based on this, a fabric device with reconfigurable connection relationships through different folding paths was designed. For the same fabric precursor with completed functional area and interconnection layout, its output topology is not fixed to a single form during the manufacturing stage. By selecting different folding methods, it can be assembled into different battery pack structures during the usage stage. Specifically, when using Type 1 folding, the device is constructed as a parallel battery pack; when using Type 2 folding, it is constructed as a series battery pack. Figure 8 a) This means that whether a device ultimately behaves in series or parallel is not entirely determined by the manufacturing stage, but can be set as needed during the usage stage through folding paths. Therefore, folding here not only triggers battery construction but also determines the final output topology. Figure 8 The physical diagram in section b further illustrates the different assembly results formed by the two folding methods. Electrochemical tests show that the series configuration exhibits a higher output voltage, while the parallel configuration has a wider current output range. Figure 8 c); The AC impedance spectrum also exhibits the typical characteristics of high series impedance and low parallel impedance ( Figure 8 d). This is consistent with the expected circuit behavior, indicating that different folding methods can stably reconstruct the device's interconnect topology.

[0094] refer to Figure 9 , Figure 9 It is a schematic diagram and performance characterization data diagram of a combination of series / parallel battery packs; Figure 8 The figures in the middle are: a schematic diagram of foldable battery packs being stacked as modules (a), and the open circuit voltages corresponding to the three stacking modes (b).

[0095] In addition to topology switching within a single device, folded battery packs are stacked and assembled as modular units. Figure 9 a). Modules are electrically connected to each other through conductive silver paste connection areas on their respective surfaces. Therefore, each folded battery pack can function as an independent functional unit, stacked and combined as needed, like building blocks. Using a four-unit series module as the basic unit, the open-circuit voltage can reach up to approximately 16 V as the number of stacked modules increases. Figure 9 b); When using a four-unit parallel module as the basic unit, the system can maintain an open-circuit voltage of approximately 4 V ( Figure 9c). When combining different types of modules, it is also possible to achieve modular output with a mix of serial and parallel processing. Figure 9 d). This indicates that fabric-based origami-structured batteries can not only reconstruct connections at the single-piece scale through folding, but also continue to stack and combine the constructed battery packs as modular units. As the number and type of modules change, the system output can be expanded in a preset manner, thereby achieving more flexible power system construction.

[0096] refer to Figure 10 , Figure 10 These are characterization data of pre-deposited NaCl on fabric separators and schematic diagrams of the applicability testing of fabric-based origami batteries in real wearable environments. Figure 10 The figures in the middle are as follows: (a) the maximum output power of a single cell under different NaCl pre-deposition amounts; (b) the polarization curves and power output curves of a single cell when activated with deionized water, beverages, milk and artificial sweat, respectively; (c) a schematic diagram of a battery integrated into a sleeve, which powers a timer under conditions of sweating during exercise and folding induced by rolling up the sleeve.

[0097] To improve the applicability of fabric-based origami batteries in real-world environments, a strategy of pre-depositing NaCl in the separator was adopted, expanding the device from one that "relies on specific electrolyte activation" to a power supply platform that can be stored in a dry state and activated on demand by multiple liquids. When activating a single cell with deionized water, the pre-deposited NaCl can dissolve rapidly under capillary action and form an electrolyte in situ. With the pre-deposited amount increasing from 0.6 mg cm⁻¹, the solution becomes more readily available. -2 Increased to 2.4 mg cm -2 The maximum output power of the battery gradually increases, and reaches a relatively stable and optimal level at a higher pre-deposition level. Figure 10 a). This indicates that the introduction of sufficient solid salt helps enhance the in-situ electrolyte generation capacity and improve ion transport processes. Based on this strategy, the battery can be activated not only by deionized water, but also by various aqueous liquids such as beverages, milk, and artificial sweat, while maintaining relatively consistent polarization behavior and power output. Figure 10 (b) indicates that the system has a strong universal activation capability for liquids.

[0098] By integrating the battery into the sleeve area, a wearable power supply module designed for scenarios involving sweating during human movement has been created. Figure 10c). When the sleeve is unfolded, the electrodes are separated, and the device is in an unconnected state. After the body sweats during exercise, the sweat wets the fabric diaphragm area. When the cuff is rolled up, the functional areas originally distributed on both sides of the fabric come into contact during the folding process, and the battery is built up and outputs electrical energy. In this scenario, sweating provides the necessary liquid for activation, while the sleeve-rolling action connects the device, connecting the two batteries in series and providing approximately 2V of voltage to stably drive the timer. This system can be directly embedded into the clothing structure and converts the sweat generated during human movement, along with the selectable folding action, into a usable power output.

[0099] refer to Figure 11 , Figure 11 This demonstrates the power supply capability of fabric-based origami batteries in outdoor carrying scenarios; Figure 11 The figures in the image are: (a) A demonstration of the process of the battery being attached to the inside of the backpack strap, and then being removed, moistened, folded, and sealed to power the positioning device; (b) Outdoor carrying status and positioning display on the mobile phone.

[0100] Furthermore, taking emergency positioning during outdoor travel as an example, the use of fabric-based origami structure batteries as portable backup power sources is further demonstrated. Figure 11 When not in use, the device can be attached to the inside of the shoulder strap via Velcro for storage in an unfolded state. When needed, it can be removed, and the diaphragm area can be moistened with external liquid. It is then folded along a pre-set crease and inserted into a slot that matches its size. External pressure applied by the slot maintains the battery's folded structure and internal contact stability, thereby providing stable power to the locator and enabling location display on the mobile phone. Compared to sleeve applications, this scenario emphasizes the device's advantages in dry-state carrying, temporary access, rapid activation, and emergency power supply in the field. The above results demonstrate that the combination of pre-deposited NaCl and origami-style structural design not only enables the fabric-based battery to adapt to sweat-driven wearable applications but also makes it a lightweight, foldable, and portable outdoor emergency power module.

[0101] refer to Figure 12 , Figure 12 This is a schematic diagram of the coupling ability test between a fabric-based origami structure battery and a real object shape. Figure 12 The images in the image are as follows: (a) a photograph of an origami umbrella with six battery cells integrated, and a demonstration of its liquid collection process and how it powers a load after being activated by folding; (b) a photograph of an origami fan with six battery cells integrated, and a demonstration of its external liquid activation process and how it outputs electrical energy after being folded.

[0102] To demonstrate the coupling capability between fabric-based origami structure batteries and real-world object forms, two types of power supply systems with "storage triggering" characteristics were constructed by integrating the devices into umbrellas and folding fans, respectively. Figure 12 In both scenarios, the battery functional areas are pre-arranged on the device surface, but are separated in the unfolded state, and the system remains in an unconnected state. During use, the liquid first wets the diaphragm area, and then the object itself folds up, causing the previously separated functional areas to come into contact and form a battery. In the umbrella scenario, the device can naturally collect liquid through the umbrella surface during rain and achieve electrode connection during the umbrella's folding process, thus directly converting the two everyday processes of rain and umbrella folding into battery activation and connection steps. In the folding fan scenario, activation is achieved by dripping external liquid onto the fan surface, and the device is constructed and output when the fan blades are folded up. In both scenarios, the umbrella and fan provide an open-circuit voltage of approximately 6V, which can stably power a small light bulb. These results demonstrate that origami batteries can achieve structural synergy with everyday objects with inherent folding / folding behaviors, transforming the object's usage into the battery assembly and operation process simultaneously.

[0103] refer to Figure 13 , Figure 13 This is a schematic diagram illustrating the large-area fabrication of batteries using a screen printing machine to power light boards. Figure 13 The figures in the image are: (a) the large-area screen printing process for fabric-based origami batteries; (b) a photograph of a large-area unfolded fabric precursor containing 180 battery cells; and (c) a photograph of a compact folding battery module (approximately 3 × 19 × 2 cm) used to drive a 100 mW LED sign.

[0104] After demonstrating that the device can achieve structural collaboration with everyday objects exhibiting folding behavior, its scale-up capability in large-area array fabrication was examined. Utilizing screen printing technology, the array fabrication of functional regions can be rapidly completed on large-area fabric substrates. Figure 13 a). Due to its low cost, suitability for mass production, and ease of scaling up, screen printing provides a technological foundation for further large-scale manufacturing. Using a 72 × 22 cm fabric substrate, 180 battery cells can be constructed at once. Figure 13 (b) After folding and integration, the array can be compressed and stored in a box of approximately 3 × 19 × 2 cm, achieving compact packaging while maintaining high-density integration. The resulting battery system can stably drive a 100mW LED light sign. Figure 13 c). The results above demonstrate that this system is not only suitable for single-device and small-module construction, but also has the potential to be further extended to large-area, low-cost, large-scale manufacturing and high-power output scenarios.

[0105] In summary, this invention proposes and verifies a fabric-based origami-structured battery. This system uses fabric as a substrate, pre-patterning a carbon cathode, zinc anode 5, fabric separator, and conductive interconnects in a two-dimensional plane. Folding achieves a controllable transformation from a planar precursor to a three-dimensional battery system. In the unfolded state, the functional areas are separated, and the device is in an unconnected state. After the separator is wetted by liquid and folded, the cathode, separator, and anode 5 come into contact, and the battery is constructed on demand and outputs electrical energy, thus achieving physical decoupling between the storage and operating states. System studies show that electrolyte concentration, external pressure, and cathode active area all affect the device output, and the unfolding-folding physical on / off mechanism helps extend the effective operating time. By controlling the unit layout and folding path in the two-dimensional plane, the device can stably form series, parallel, and hybrid battery packs after folding, and different output topologies can be achieved from the same precursor. The folded battery packs can also be stacked and combined as modular units to achieve higher-order system expansion. These results demonstrate that folding in this system not only enables morphological transformation but also determines the contact of functional areas, circuit connections, and the final spatial integration method. To enhance the device's applicability in real-world scenarios, pre-deposited NaCl is introduced into the separator, expanding it from a system dependent on specific electrolyte activation to a power supply platform capable of dry-state storage and on-demand activation by various liquids. Based on this strategy, the device can be activated by various aqueous liquids such as deionized water, beverages, milk, and artificial sweat, and further integrated into practical applications such as sleeves, umbrellas, and folding fans. Utilizing screen printing technology, 180 battery cells can be fabricated simultaneously on a 72 × 22 cm fabric and compressed into a box of approximately 3 × 19 × 2 cm after folding and integration, stably driving a 100 mW LED light sign. In summary, the fabric-based origami structure battery unifies physical on / off switching, two-dimensional pre-programmed layout, and three-dimensional high-density integration on the same device platform, providing a new design concept for flexible power supplies to move from two-dimensional devices to three-dimensional reconfigurable systems, and demonstrating application potential in wearable electronics, smart fabrics, and portable emergency power supply.

[0106] This invention discloses a fabric-based origami-structure battery fabrication method. The method involves cutting the fabric into a predetermined shape and size, and then fabricating a carbon cathode on its surface via screen printing. Scanning electron microscopy (SEM) reveals that the cured carbon paste tightly coats the fabric fiber surface, forming a continuous and uniform conductive layer with an interfacial resistance of approximately 46 Ω. Since the carbon paste does not completely penetrate the fabric, the unwetted half of the fabric serves as a separator layer 2, exhibiting good hydrophilicity. Cross-sectional SEM images clearly show the layered structure of both layers. This integrated electrode / separator design based on the fabric body fully utilizes the inherent thickness and porous structure of the fabric, simplifying the manufacturing process and reducing costs while satisfying ion transport requirements. All areas except the carbon electrode and separator are laminated with wax to form a hydrophobic barrier 4, exhibiting good hydrophobicity. This effectively constrains the electrolyte distribution range and limits ion transport channels, laying the foundation for subsequent multi-unit independent operation and complex circuit integration. Finally, ultra-thin double-sided adhesive is used to fix zinc foil in specific positions, ensuring close contact with the fabric fibers, completing the electrode arrangement on a two-dimensional plane. In this invention, the cathode, anode 5, and separator regions are all arranged with equal dimensions to ensure precise alignment during folding, thereby maximizing the effective contact area of ​​the electrodes. The battery's operation relies on the structural transformation triggered by folding. In the unfolded state, the cathode, anode 5, and separator are spatially separated, and the device is in an unconnected state, thus avoiding continuous energy consumption in the connected state. Electrolyte is added to the separator, and after complete folding along predefined creases, these functional layers are brought into close contact by clamping, forming a complete electrochemical battery and triggering the oxidation reaction (Zn). -2 e-→Zn 2+ ) and reduction reaction (O2 + 2H2O + 4e) - →4OH - This provides an open-circuit voltage of 1-1.2V. This mechanically triggered "on-off" mechanism decouples the storage state from the operating state, avoiding the continuous consumption of traditional primary batteries in the connected state, and enabling on-demand construction and on-demand startup. This method enables the fabrication of fabric-based batteries with on-demand construction and programmable topology reconfiguration.

[0107] Secondly, please refer to Figures 21-22 The present invention also provides a fabric-based origami structure battery, comprising a polyester fiber fabric 1, a separator layer 2, a cathode layer 3, a hydrophobic barrier 4, and an anode 5; the cathode layer 3 is attached to the surface of the polyester fiber fabric 1 and partially embedded in the thickness direction; the separator layer 2 is disposed on the thickness portion of the polyester fiber fabric 1 directly below the cathode layer 3 and is integrally connected to the cathode layer 3; the hydrophobic barrier 4 is disposed on the surface of the polyester fiber fabric 1 in the area other than the cathode layer 3 and the separator layer 2, adjacent to the cathode layer 3 and the separator layer 2 but not overlapping them; the anode 5 is attached to the surface of the polyester fiber fabric 1.

[0108] This invention discloses a fabric-based origami-structured battery. Using fabric as a substrate, the battery functional units (cathode, anode 5, separator, and wires) are pre-patterned on a two-dimensional plane, and a controllable transformation from a planar precursor to a three-dimensional battery system is achieved through folding. Using a Zn-air battery system as a model, a fabric-based battery is constructed with screen-printed carbon as the cathode, the fabric body as the separator, zinc foil as the anode 5, and screen-printed silver as the wires. In the unfolded state, the functional areas are separated, and the device is in an unconnected state. After the separator is wetted by liquid and folded, the cathode, separator, and anode 5 come into contact, and the battery is constructed as needed to output electrical energy, thus achieving physical decoupling between the storage state and the operating state. Based on the pre-programmed layout and folding path design in the two-dimensional plane, this system can not only form a single cell but also stably construct series, parallel, and hybrid structures of multiple cells, achieving adjustable voltage, current, and power output. To eliminate reliance on pre-prepared electrolytes, this application pre-deposits NaCl in the separator, expanding the device from a system requiring external ionic activation to a power supply platform capable of dry storage and on-demand triggering by various liquids. Building upon this, 180 battery cells are pre-embedded on a 72 × 22 cm fabric and fabricated over a large area using a single screen printing process. After folding and integration, the battery can stably drive a 100 mW LED light sign, demonstrating its potential for low-cost, large-scale manufacturing. This system can also be further integrated into everyday objects with natural opening / closing behaviors, wearable clothing, and portable emergency carriers, directly transforming the liquid acquisition and structural folding process into battery activation and connection steps. This fabric-based origami-structure battery provides a novel power solution for wearable electronics, smart fabrics, and portable energy fields, offering flexibility, programmability, efficient integration, and large-scale manufacturing potential.

[0109] The above-disclosed embodiments are merely one or more preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art can understand that all or part of the processes for implementing the above embodiments and equivalent changes made in accordance with the claims of this application still fall within the scope of this application.

Claims

1. A method for fabricating a paper-folding structure battery based on fabric, characterized in that, include: Using screen printing, conductive carbon paste is used as the printing material on the surface of polyester fiber fabric. A carbon cathode layer is formed in the cathode area by scraping. The printing process parameters are controlled so that the penetration depth of the conductive carbon paste reaches 30%-70% of the total thickness of the polyester fiber fabric. The other half of the polyester fiber fabric thickness that is not wetted by the conductive carbon paste serves as the diaphragm layer. After printing, the polyester fiber fabric is dried to solidify the carbon paste, thus completing the integrated preparation of the cathode and diaphragm. A wax lamination method is used to transfer molten paraffin to the fabric surface, excluding the cathode area and the diaphragm area, using a perforated template to form a hydrophobic barrier with a water contact angle ≥120°. The zinc foil is cut into square blocks of the same size as the cathode and then attached to the pre-marked anode area on the fabric substrate using ultra-thin double-sided tape. Pre-fabricated crease lines are made between adjacent functional areas on the fabric at a predetermined distance from the electrode edge, with the crease depth controlled to be 10%-50% of the total fabric thickness; NaCl aqueous solution was added dropwise to the membrane area to fully wet the entire membrane and then dried so that NaCl precipitated in solid crystal form and remained in the pores of the fabric fibers, thus obtaining a pre-deposited membrane and fabric-based origami structure battery. An activation liquid is added dropwise to the pre-deposited membrane area. The liquid is drawn into the membrane through capillary action and dissolves the NaCl solid, generating an electrolyte solution in situ. The battery is then activated by folding the fabric along the creases to power electronic devices.

2. The method for fabricating a paper-folding structure battery based on fabric as described in claim 1, characterized in that, Using screen printing, conductive carbon paste is applied to the surface of a polyester fiber fabric. A carbon cathode layer is formed in the cathode area by a squeegee process. The printing parameters are controlled to ensure the conductive carbon paste penetrates to 30%-70% of the total thickness of the polyester fiber fabric. The remaining half of the polyester fiber fabric thickness, not wetted by the conductive carbon paste, serves as the separator layer. After printing, the polyester fiber fabric is dried to solidify the carbon paste, thus completing the integrated preparation of the cathode and separator. The screen printing uses a 300-mesh screen printing plate, with a squeegee pressure of 0.01-0.1 MPa, a squeegee angle of 60°-80°, and a printing speed of 50-150 mm / s. The printing method involves first performing three reciprocating strokes in the horizontal direction, then rotating the squeegee 90° and performing three reciprocating strokes in the vertical direction. The drying conditions are: drying at 90 ℃ for 30 min to solidify the carbon paste.

3. The method for fabricating a paper-folding structure battery based on fabric as described in claim 1, characterized in that, In the step of using a wax lamination method to transfer molten paraffin to the fabric surface (excluding the cathode and diaphragm areas) using a perforated template to form a hydrophobic barrier with a water contact angle ≥120°, the specific process of the wax lamination method is as follows: Solid paraffin wax is heated to 120 ℃ to completely melt it. A perforated template made of A4 paper is immersed in the molten paraffin wax for 2-3 seconds. After cooling, the template containing paraffin wax is attached to the surface of the fabric. Then, it is hot-pressed at 120 ℃ and 0.1-0.5 MPa for 5 seconds. After hot pressing, the template is removed to obtain the hydrophobic barrier.

4. The method for fabricating a paper-folding structure battery based on fabric as described in claim 1, characterized in that, In the step of cutting zinc foil into square pieces of the same size as the cathode and attaching the zinc foil to the pre-marked anode area on the fabric substrate using ultra-thin double-sided tape, The zinc foil has a thickness of 0.02 mm, and the ultra-thin double-sided tape has a thickness of 0.01 mm.

5. The method for fabricating a paper-folding structure battery based on fabric as described in claim 1, characterized in that, In the step of pre-faking crease lines between adjacent functional areas on the fabric at a predetermined distance from the electrode edge, with the crease depth controlled to be 10%-50% of the total fabric thickness,... The creases are prefabricated by manually bending them back and forth 1-5 times, or by using indentation, hot pressing, or molding.

6. The method for fabricating a paper-folding structure battery based on fabric as described in claim 1, characterized in that, A NaCl aqueous solution is added dropwise to the membrane region to fully wet the entire membrane, followed by drying. This allows the NaCl to precipitate as solid crystals and remain in the pores of the fabric fibers, resulting in a pre-deposited membrane. This process is part of the step in fabricating a paper-folding structure battery based on fabric. The NaCl aqueous solution is a 2 mol / L NaCl aqueous solution, and the amount added is 40 μL; the drying conditions are: drying in an environment of 20-30℃ and 30%-60% RH for 6-24 hours.

7. The method for fabricating a paper-folding structure battery based on fabric as described in claim 1, characterized in that, In the process of adding an activation liquid dropwise to the pre-deposited membrane area, the liquid is drawn into the membrane through capillary action and dissolves the NaCl solid, generating an electrolyte solution in situ. Then, the battery is activated by folding the fabric along the creases, thus powering the electronic device. The activating liquid is any one of deionized water, sweat, milk, or juice.

8. A fabric-based origami structure battery, prepared using the fabric-based origami structure battery preparation method as described in any one of claims 1-7, characterized in that, The device includes a polyester fiber fabric, a separator layer, a cathode layer, a hydrophobic barrier, and an anode. The cathode layer is attached to the surface of the polyester fiber fabric and partially embedded in its thickness direction. The separator layer is disposed on the thickness portion of the polyester fiber fabric directly below the cathode layer and is integrally connected to the cathode layer. The hydrophobic barrier is disposed on the surface of the polyester fiber fabric in the area excluding the cathode layer and the separator layer, adjacent to the cathode layer and the separator layer but not overlapping them. The anode is adhered to the surface of the polyester fiber fabric.

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