Biodegradable Extruded Sealing Layer for Moisture-Stable Printed Batteries

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Solution Overview

Problem

Conventional batteries generate significant environmental waste due to their non-biodegradability, and existing sealing layers for electrochemical devices are often non-environmentally friendly, posing challenges in maintaining moisture levels and compatibility with all-printed battery technologies.

Innovation Solution

Development of a biodegradable extruded sealing layer composition using crosslinked polymers like poly(ε-caprolactone) and polylactic acid, incorporating fillers such as cellulose and clay, applied through an extrusion process to create a moisture barrier for electrochemical devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional non-biodegradable sealing materials are used, then sealing effectiveness is improved, but environmental compatibility deteriorates

Engineering Contradiction:

Improvesealing effectivenessVSAvoidenvironmental compatibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of sealing materials from conventional non-biodegradable polymers to biodegradable polymers (polylactic acid, polyglycolic acid, polycaprolactone) and natural materials (cellulose, chitosan, alginate). This parameter change maintains sealing effectiveness while improving environmental compatibility by enabling biodegradation and compostability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material formulations combining biodegradable polymers with natural fillers (cellulose, chitosan, alginate, starch) and functional additives. These composites achieve the required mechanical strength and sealing performance while maintaining biodegradability, resolving the contradiction between reliability and environmental compatibility.

Inventive Principle:

Principle #40Composite materials

2Reliability

If adhesives and sealants are used for sealing, then moisture barrier performance is improved, but compatibility with all-printed approach deteriorates

Engineering Contradiction:

Improvemoisture barrier performanceVSAvoidcompatibility with all-printed approach

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional adhesive-based sealing with a direct printing approach where sealing layers are deposited directly onto electrode structures using printing techniques. This eliminates the need for separate adhesive application steps, improving compatibility with all-printed battery manufacturing while maintaining moisture barrier performance through the printed material itself.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges the sealing function with the structural components of the battery by making the sealing layers integral to the printed battery structure. The sealing material is combined with conductive and active materials in a single printed structure, eliminating separate adhesive layers and simplifying the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If thin film printed batteries are used, then flexibility and cost are improved, but moisture retention capability deteriorates

Engineering Contradiction:

ImproveflexibilityVSAvoidmoisture retention capability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs flexible thin film sealing layers made from biodegradable polymers and natural materials that conform to the thin film battery structure. These flexible sealing films maintain the moisture barrier function while preserving the flexibility and lightweight characteristics essential for wearable and portable applications.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent applies sealing materials with locally optimized properties at critical moisture exposure points in the thin film battery structure. By concentrating enhanced moisture barrier properties where most needed (at interfaces and edges) while maintaining overall flexibility, the patent resolves the contradiction between moisture retention and flexibility.

Inventive Principle:

Principle #3Local quality

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 while ensuring the integrity of electrochemical devices, aligning with environmentally friendly and flexible battery requirements, and facilitating the production of compostable batteries.

Implementation Method 1

A robust sealing layer or gasket can be used to prevent drying out of the cells and other sections or layers within an electrochemical device

Methodology Applied

Scientific EffectPhysical barrier:

Data Source

PatentUS20260081274A1Extruded sealing layer for biodegradable electrochemical device and methods thereof

Publication Date: 2026.03.19 GENESEE VALLEY INNOVATIONS LLC

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.