High Current Thin Electrochemical Cell via Co-Planar Layering
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Solution Overview
Problem
Conventional low-profile batteries fail to meet the requirements for low-cost, low-capacity, thin, flat, and versatile power sources needed for modern applications such as active RFID tags and sensors, which demand higher currents and reliable performance across various temperatures.
Innovation Solution
A method of manufacturing a high current thin electrochemical cell using a co-planar construction with multiple cathode and anode layers separated by a dielectric layer, sealed within a picture frame structure, utilizing a viscous electrolyte and printed on flexible substrates to enable high-speed, high-volume production of thin, flexible batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional low-profile batteries are used, then the device structure is simple and manufacturing is easy, but the current delivery capability is insufficient for modern applications
Solution Approach 1:
The battery is divided into multiple discrete layers (first cathode layer, dielectric layer, anode layer, second cathode layer) stacked in sequence. This segmentation allows each layer to be optimized independently for its specific function while collectively achieving high current delivery capability without excessive structural complexity
Solution Approach 2:
The patent implements a nested structure where the anode layer is positioned between two cathode layers, and the dielectric layer is integrated within the stack. This nesting arrangement maximizes space utilization and enables multiple electrochemical reactions to occur simultaneously, enhancing power output while maintaining a compact form factor
2Length of moving object
If thin and flat battery design is implemented, then portability and low profile are improved, but manufacturing precision and quality control become more difficult
Solution Approach 1:
A release liner is applied to the anode layer before stacking, and a sealing layer is pre-positioned around the peripheral edges. These preliminary actions protect the thin layers during handling and assembly, preventing misalignment and damage while enabling precise positioning in the final stacked configuration
Solution Approach 2:
The patent utilizes thin film structures for the cathode layers, anode layer, and sealing layer. These flexible thin films can be easily manipulated and positioned with high precision during assembly, maintaining the thin overall profile while enabling accurate layer alignment through their flexibility and conformability
3Reliability
If multiple layers and sealing structures are added to improve reliability, then current delivery and temperature performance improve, but manufacturing cost and process complexity increase
Solution Approach 1:
The sealing layer is designed to automatically seal the electrolyte within the battery structure through its inherent adhesive properties and geometric configuration. This self-sealing mechanism eliminates the need for additional complex sealing equipment or multi-step sealing processes, maintaining reliability while simplifying manufacturing
Solution Approach 2:
The battery employs composite material structures where the sealing layer combines adhesive, barrier, and structural properties. This composite approach achieves reliable sealing and temperature performance through material composition rather than complex structural arrangements, reducing manufacturing complexity and cost
4Ease of manufacture
If disposable and environmentally friendly materials are used, then environmental impact is reduced and cost is lowered, but performance and durability may be compromised
Solution Approach 1:
The patent optimizes the thickness, composition, and electrochemical properties of each layer (cathode, anode, dielectric, sealing) to maximize current delivery capability within the constraints of disposable materials. By carefully adjusting these parameters, high power output is achieved despite using cost-effective, environmentally friendly materials
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 enables the production of thin, flexible batteries that can deliver higher currents reliably, maintain performance across various temperatures, and are cost-effective, suitable for disposable applications, while being environmentally friendly.
Implementation Method 1
an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer
Implementation Method 2
providing a dielectric layer on said cathode collector layer, and providing an anode layer on said dielectric layer
Data Source
AI summary
A battery including at least one electrochemical cell for generating an electrical current is provided, along with its method of manufacture. In one example, the electrochemical cell is provided on a first substrate and includes an anode and a plurality of cathodes. At least a portion of said anode is located between an adjacent two of said plurality of cathodes. In one example method of manufacture, the electrochemical cell is made via a printing press process.