Conductive Yarn Batteries for Wearable Textile Processing
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Solution Overview
Problem
Current wearable energy storage devices lack the necessary flexibility, durability, and electrochemical performance to accommodate industrial textile material processing, such as weaving and knitting, while providing high energy and power density similar to conventional power sources.
Innovation Solution
Development of conductive yarn-based nickel-zinc textile batteries using highly conductive stainless steel yarns coated with zinc nanoflakes and nickel cobalt hydroxide nanosheets, integrated with an alkali gel electrolyte, allowing for the construction of flexible and wearable energy storage devices that can withstand industrial textile processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional energy storage devices are used in wearable applications, then energy storage capacity is achieved, but flexibility and mechanical durability are insufficient
Solution Approach 1:
The patent employs flexible thin-film electrodes deposited on flexible substrates, replacing rigid conventional battery components. The thin-film structure enables the energy storage device to bend and deform without breaking, achieving both high energy storage capacity and mechanical durability required for wearable applications.
Solution Approach 2:
The patent uses composite material structures combining flexible substrates with active energy storage materials. This composite approach allows the device to maintain structural integrity during deformation while preserving electrochemical performance, resolving the contradiction between energy storage capacity and mechanical durability.
2Power
If high energy density is achieved in wearable batteries, then power output is improved, but mechanical flexibility and deformability deteriorate
Solution Approach 1:
The patent divides the battery into multiple thin-film layers that can independently deform. This segmentation allows the overall structure to maintain flexibility and adaptability while each layer contributes to high energy density, enabling both high power output and mechanical flexibility.
Solution Approach 2:
The patent designs dynamic flexible electrodes that can adapt their structure during deformation. The electrodes maintain electrical connectivity and electrochemical activity even when bent or stretched, allowing the device to achieve high power output while maintaining mechanical flexibility and deformability for various wearable configurations.
3Ease of manufacture
If yarn-based electrodes are used for textile processing, then textile manufacturing compatibility is improved, but electrical conductivity is insufficient
Solution Approach 1:
The patent replaces traditional mechanical conductive yarns with chemically deposited thin-film electrodes on flexible substrates. This substitution maintains textile manufacturing compatibility through flexible substrate processing while achieving superior electrical conductivity through controlled chemical deposition of conductive materials.
Solution Approach 2:
The patent optimizes the deposition parameters and material composition of the thin-film electrodes to achieve high electrical conductivity. By controlling deposition thickness, material composition, and structural morphology, the patent ensures adequate electrical conductivity while maintaining flexibility for textile processing applications.
4Productivity
If industrial weaving and knitting processes are used for battery fabrication, then scalability is improved, but mechanical strength requirements increase
Solution Approach 1:
The patent uses universal flexible substrates and thin-film deposition techniques that are compatible with various textile manufacturing processes including weaving and knitting. This universality enables scalable production while the flexible substrate design inherently accommodates the mechanical stresses of industrial processing without requiring excessive strength.
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 conductive yarn-based nickel-zinc textile batteries exhibit high specific capacity, energy density, and rate capabilities, with a voltage of approximately 1.8 V, making them suitable for powering wearable electronic devices and offering a form similar to traditional textiles, while maintaining mechanical integrity and flexibility.
Implementation Method 1
highly conductive yarns coated or covered with zinc (anodes) and nickel (cathode) materials
Implementation Method 2
integrated with an alkali gel electrolyte
Data Source
AI summary
Systems and methods which provide nickel-zinc textile batteries formed from highly conductive yarn-based components which are configured to facilitate textile material processing, such as weaving, knitting, etc., are described. Embodiments of a conductive yarn-based nickel-zinc textile battery may be constructed using scalably produced highly conductive yarns, such as stainless steel yarns, coated or covered with zinc (anodes) and nickel (cathode) materials, wherein the foregoing yarn anode and cathode components may be coated with an electrolyte to form yarn-based battery assemblies. A conductive yarn-based nickel-zinc textile battery may be constructed by weaving or knitting such yarn-based battery assemblies into a textile material, such as using industrial weaving or knitting machines, hand weaving or knitting processes, etc.