Flexible Micro-Battery Biocompatible Packaging
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Solution Overview
Problem
Biocompatible micro-batteries for medical devices face challenges in maintaining biocompatibility, mechanical robustness, and flexibility, especially when exposed to saline solutions, due to high surface area to volume ratios and osmotic pressure differences, and conventional batteries are not suitable for flexible devices with rigid casings that limit dimensions and functionality.
Innovation Solution
A flexible electrochemical micro-battery design with a cylindrical anode and planar cathode, using a zinc anode and manganese dioxide cathode, and an aqueous neutral electrolyte with zinc acetate, encapsulated in biocompatible packaging that prevents water and oxygen migration, allowing for flexible shapes and operation in saline environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional batteries with rigid casings are used, then structural strength is improved, but flexibility and adaptability to flexible devices deteriorate
Solution Approach 1:
The patent replaces rigid battery casings with flexible packaging materials that can bend and conform to flexible device geometries. The flexible packaging encapsulates the battery components while maintaining structural integrity, enabling the battery to be integrated into flexible medical devices without compromising strength or flexibility.
2Volume of moving object
If micro-battery size is reduced to fit flexible devices, then device compactness is improved, but reliability and containment performance deteriorate due to high surface area to volume ratios
Solution Approach 1:
The patent employs composite packaging structures that combine multiple materials with complementary properties to enhance containment performance in miniaturized batteries. The composite packaging provides improved barrier properties and mechanical strength despite the reduced battery size and high surface area to volume ratio, ensuring reliable containment of electrolyte and prevention of component leaching.
3Object-affected harmful factors
If biocompatible materials are used for miniaturized power sources, then biocompatibility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent selects biocompatible materials that serve multiple functions simultaneously. For example, the flexible packaging material provides both biocompatibility for implantable applications and structural containment functions. The electrolyte solution is formulated to be both biocompatible and provide necessary ionic conductivity, reducing the need for separate specialized components and simplifying manufacturing.
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 design provides a biocompatible, mechanically robust, and flexible micro-battery that maintains power delivery and integrity over a long shelf life, preventing component leaching and swelling, while accommodating flexible device requirements and maintaining effective energy supply in saline environments.
Implementation Method 1
an electrolyte positioned generally surrounding both the anode and the cathode and within the predetermined space to provide ionic conductivity between the anode and the cathode
Implementation Method 2
biocompatible packaging that prevents water and oxygen migration
Implementation Method 3
osmotic pressure differences
Data Source
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AI summary
Designs, strategies and methods for forming micro-batteries are described. In some examples, ultrasonic welded seals may be used to seal battery chemistry within the micro-battery. In some further examples, the micro-battery is encapsulated by a copper film where at least a portion of the copper film is formed by electroless plating.