Biodegradable Extruded Sealing Layer for Moisture-Resistant Batteries
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Solution Overview
Problem
There is a need for biodegradable and environmentally friendly sealing layers for electrochemical devices, particularly batteries, that maintain moisture integrity and are compatible with all-printed manufacturing processes, as conventional adhesives and sealants are non-biodegradable and hinder recyclability.
Innovation Solution
A biodegradable extruded sealing layer composition using crosslinked polymers, such as poly(ε-caprolactone) and polylactic acid, with fillers like cellulose and clay, is applied between substrates in a laterally non-continuous pattern to form a moisture barrier, utilizing 3D printing for precise application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional adhesives and sealants are used to create a sealing layer, then moisture barrier performance is improved, but biodegradability and environmental sustainability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the sealing layer by using biodegradable polymers (PLA, PCL, PHA) instead of conventional non-biodegradable adhesives. This parameter change maintains the moisture barrier function while enabling biodegradation, thus resolving the contradiction between reliability and environmental harm.
Solution Approach 2:
The patent creates a composite sealing layer by combining biodegradable polymers with natural fillers (cellulose, starch, clay). This composite approach enhances the moisture barrier properties of the biodegradable material while maintaining its environmental sustainability, simultaneously addressing both moisture protection and biodegradability requirements.
2Ease of manufacture
If all-printed manufacturing processes are used, then ease of manufacture and scalability are improved, but achieving defect-free sealing layers with controlled thickness becomes more difficult
Solution Approach 1:
The patent replaces traditional mechanical sealing methods with a printed sealing layer approach using extrusion-based 3D printing. This substitution enables scalable manufacturing while achieving controlled thickness and defect-free sealing through digital control of the printing process parameters such as extrusion rate, temperature, and deposition path.
Solution Approach 2:
The patent controls the sealing layer quality by optimizing printing parameters including extrusion temperature, material viscosity, deposition speed, and layer thickness. These parameter changes enable precise control over sealing layer formation, ensuring defect-free production with consistent thickness across large-scale manufacturing.
3Object-affected harmful factors
If biodegradable polymers are used in the sealing layer, then environmental sustainability is improved, but moisture barrier performance and sealing reliability may deteriorate
Solution Approach 1:
The patent enhances the moisture barrier properties of biodegradable polymers by incorporating hydrophobic fillers such as clay, cellulose, and starch into the polymer matrix. This composite structure creates tortuous paths for moisture penetration, improving barrier performance while maintaining the biodegradability of the sealing layer.
Solution Approach 2:
The patent applies different filler types and concentrations in specific regions of the sealing layer to optimize local moisture barrier properties. By tailoring the composition locally, the sealing layer achieves enhanced moisture resistance in critical areas while maintaining overall biodegradability and environmental sustainability.
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 solution provides a flexible, moisture-resistant, and biodegradable sealing layer that maintains device integrity while ensuring environmental sustainability by facilitating recyclability and reducing waste.
Implementation Method 1
A sealing layer composition is disclosed, the sealing layer composition including a biodegradable polymer and a filler, and where the sealing layer composition is extruded
Implementation Method 2
the extruded sealing layer composition includes a crosslinked polymer
Implementation Method 3
the extruded sealing layer composition includes a biodegradable material
Data Source
AI summary
An electrochemical device including a first substrate layer is disclosed. The electrochemical device also includes an anode disposed upon the first substrate layer. The device also includes a second substrate layer. The electrochemical device also includes a cathode disposed upon the second substrate layer and an electrolyte composition disposed between and in contact with the anode and the cathode. The electrochemical device also includes an extruded sealing layer composition disposed between the first substrate layer and the second substrate layer. A sealing layer composition and a method of producing a sealing layer is also disclosed.