3D Printed Substrate for Flexible Thin-Film Batteries
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Solution Overview
Problem
Existing flexible batteries face challenges in adhering smoothly to curved or irregular surfaces due to the use of flat plastic substrates, often requiring adhesives or encapsulants that can cause malfunctions and increase costs.
Innovation Solution
The development of a flexible printed battery with a 3D printed substrate that can be thermally bonded without adhesives or encapsulants, allowing the substrate to match the shape and surface of the object, eliminating the need for additional adhesives and enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If flat plastic substrates are used for flexible batteries, then the battery structure is simple and easy to manufacture, but the battery cannot adhere smoothly to curved or irregular surfaces
Solution Approach 1:
The patent applies curvature by transitioning from flat plastic substrates to 3D printed substrates that can be manufactured with curved and irregular shapes to match the target surface. The 3D printing process enables direct fabrication of substrates with the required curvature, eliminating the need for flat substrates that cannot conform to complex surfaces.
Solution Approach 2:
The patent changes the manufacturing parameters and material properties by adopting 3D printing technology. This enables the substrate to be printed with varying thickness, curvature, and surface geometry, transforming it from a rigid flat structure to a flexible conformable structure that adapts to the target surface shape.
2Reliability
If adhesives or encapsulants are used to bond the battery to curved surfaces, then the battery can adhere to the surface, but malfunctions and costs increase
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the battery structure. By designing the 3D printed substrate with integral bonding features and direct thermal bonding capability, the need for separate adhesive materials is removed, thereby eliminating the source of adhesive-related malfunctions and additional costs.
Solution Approach 2:
The 3D printed substrate provides self-bonding capability through thermal bonding, where the substrate material itself serves as the bonding agent. The substrate is designed with properties that enable direct thermal bonding to the target surface without requiring external adhesives, making the system self-sufficient.
3Adaptability or versatility
If 3D printed substrates are used, then the battery can adhere seamlessly to complex surfaces without adhesives, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the substrate manufacturing and surface adaptation functions into a single 3D printing process. The substrate is printed directly in the required curved shape, combining formability and adaptability in one manufacturing step, rather than requiring separate forming and bonding operations.
Solution Approach 2:
The 3D printed substrate serves multiple functions: it provides structural support, enables surface conformability through its curved geometry, and facilitates direct thermal bonding. This multi-functionality reduces the need for additional components and simplifies the overall manufacturing process despite the advanced printing technology used.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D printed substrate enables the battery to adhere seamlessly to complex surfaces, maintaining flexibility and eliminating the need for adhesives, thus reducing costs and preventing potential malfunctions.
Implementation Method 1
The 3D printed substrate enables the battery to adhere seamlessly to complex surfaces
Data Source
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AI summary
A method for printing a flexible printed battery is disclosed. For example, the method includes printing, via a three-dimensional (3D) printer, a first substrate of the flexible thin-film printed battery, printing a first current collector on the first substrate, printing a first layer on the first current collector, printing, via the 3D printer, a second substrate, printing a second current collector on the second substrate, printing a second layer on the second current collector, and coupling the first substrate and the second substrate around a paper separator membrane moistened with an electrolyte that is in contact with the first layer and the second layer.