3D-Printed Biodegradable Sealing Layer for Moisture-Stable Batteries
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Solution Overview
Problem
The increasing demand for portable power sources has led to a surge in battery production, resulting in toxic waste due to the lack of environmentally friendly and biodegradable batteries, particularly for disposable batteries used in applications like IoT devices and healthcare monitoring, where conventional non-biodegradable adhesives and sealants fail to maintain hydration and prevent drying out in electrochemical devices.
Innovation Solution
A biodegradable electrochemical device with a fused deposition modeling (FDM) printed sealing layer composed of materials like poly(ε-caprolactone) (PCL), polylactic acid (PLA), and polyhydroxybutyrate (PHB) is developed, which forms a moisture barrier and can be used in a laterally non-continuous pattern between substrates to prevent moisture loss, addressing the need for a compostable and flexible sealing solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional non-biodegradable adhesives and sealants are used to seal electrochemical devices, then the sealing effectiveness and moisture barrier are improved, but the environmental sustainability and biodegradability deteriorate
Solution Approach 1:
The patent changes the material parameters of the sealing layer by using biodegradable polymers (PCL, PLA, PHB) instead of conventional non-biodegradable adhesives. This material substitution maintains the sealing function while improving environmental sustainability and enabling biodegradation of the electrochemical device.
Solution Approach 2:
The patent employs composite material strategies by formulating sealing layers from biodegradable polymer compositions that combine multiple materials (PCL, PLA, PHB) to achieve both adequate sealing performance and biodegradability. The composite approach allows optimization of both protective function and environmental compatibility.
2Object-affected harmful factors
If FDM printed sealing layer is used to prevent moisture loss, then the biodegradability and environmental friendliness are improved, but the sealing robustness and moisture barrier performance may deteriorate
Solution Approach 1:
The patent applies local quality by using laterally non-continuous sealing layer patterns where the sealing material is strategically placed only in specific locations rather than uniformly across the entire device. This approach provides adequate moisture barrier performance at critical sealing points while reducing overall material usage and maintaining biodegradability.
Solution Approach 2:
The patent employs thin film sealing layers made from biodegradable polymers that are deposited via FDM printing. These thin films provide sufficient moisture barrier performance for the application while maintaining flexibility and biodegradability, overcoming the assumption that robust sealing requires thick non-biodegradable materials.
3Object-affected harmful factors
If all-printed approach with biodegradable materials is used, then the environmental sustainability is improved, but the manufacturing precision and defect-free quality may deteriorate
Solution Approach 1:
The patent applies preliminary action by optimizing the FDM printing process parameters and material formulations before production. The biodegradable polymer compositions are pre-formulated with appropriate rheological properties and the printing process is pre-calibrated to achieve consistent, defect-free sealing layers with controlled thickness and uniform properties.
Solution Approach 2:
The patent replaces conventional mechanical sealing methods (adhesives, glues) with FDM additive manufacturing technology. This substitution enables precise digital control over sealing layer geometry, thickness, and placement, achieving manufacturing precision comparable to or exceeding traditional methods while using biodegradable materials throughout the process.
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 biodegradable sealing layer effectively prevents moisture loss and provides a robust, defect-free, and uniformly thick barrier, enhancing the longevity and environmental sustainability of electrochemical devices such as batteries, while being suitable for all-printed approaches and flexible applications.
Implementation Method 1
The fused deposition modeling (FDM) printed sealing layer composition may include a biodegradable material and forms a moisture barrier around the electrochemical device
Data Source
AI summary
An electrochemical device is disclosed, including a first substrate layer. 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 a sealing layer which may include a 3D-printed sealing layer composition disposed between the first substrate layer and the second substrate layer. A 3D-printed sealing layer and a method of producing a sealing layer is disclosed.