Layered Battery With Adhesive Electrolyte Separator
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Solution Overview
Problem
Conventional thin, flexible batteries require a separator between the anode and cathode, which increases battery thickness and is prone to leakage, especially in wearable applications where a solid electrolyte is not used.
Innovation Solution
A thin, bendable, printed battery structure without a separator, utilizing a water-soluble electroactive material and a water-insoluble polymer matrix in an adhesive intermediate layer to prevent short-circuiting, combined with a flexible package that encases the electrodes, eliminating the need for a conventional separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a conventional separator is used between anode and cathode, then electrical contact prevention is achieved, but battery thickness increases
Solution Approach 1:
The patent merges the separator and electrolyte functions into a single intermediate layer. This layer contains both the separator material (to prevent electrical contact) and the electrolyte (to enable ion transport), eliminating the need for separate components and reducing overall battery thickness while maintaining short-circuit prevention
Solution Approach 2:
The intermediate layer is constructed as a composite material system combining separator polymers (such as polyolefin or cellulose) with electrolyte components (liquid, gel, or solid). This composite structure provides both the physical separation needed to prevent short circuits and the ionic conductivity required for battery operation, achieving dual functionality in a single thin layer
2Reliability
If a liquid electrolyte is used in the separator, then ionic conductivity is improved, but leakage risk increases in flexible batteries
Solution Approach 1:
The patent changes the physical state parameter of the electrolyte from liquid to gel or solid form. This phase transition maintains ionic conductivity while eliminating the leakage hazard, making the battery suitable for flexible and wearable applications where the structure may be bent or deformed
Solution Approach 2:
The electrolyte is integrated into the separator matrix as a composite system. Liquid electrolyte is absorbed into the porous separator structure, or gel/solid electrolyte is combined with separator polymers, creating a unified structure where the electrolyte is contained and cannot leak while maintaining electrical conductivity
3Reliability
If a separator is included in the battery structure, then short-circuit prevention is achieved, but manufacturing complexity increases
Solution Approach 1:
The separator and electrolyte are combined into a single intermediate layer component, reducing the number of parts in the battery assembly. This simplification maintains the essential function of preventing short circuits while reducing structural complexity and facilitating easier manufacturing
Solution Approach 2:
The intermediate layer is designed to perform multiple functions simultaneously: it acts as both the separator (preventing electrical contact) and the electrolyte reservoir (enabling ion transport). This multi-functional design eliminates the need for separate dedicated components, simplifying the overall battery structure
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 results in a thinner, more reliable, and safer battery that prevents leakage and short-circuiting, suitable for wearable electronics, with enhanced mechanical strength and bio-friendly materials, allowing for integration with flexible devices without safety concerns.
Implementation Method 1
The intermediate layer includes a water-insoluble polymer matrix having sufficient rigidity to prevent contact of the first layer and the second layer
Implementation Method 2
An adhesive, UV-curable intermediate layer is adhered to the first layer on a first side of the intermediate layer and is adhered to the second layer on a second side of the intermediate layer
Implementation Method 3
A flexible package encases the first, second, and intermediate layers
Data Source
AI summary
The present invention provides a thin, bendable, printed, layered primary battery structure without a battery separator. The battery includes a first layer including a printed positive electrode. A second layer includes a negative electrode material which may be a printed negative electrode or a metal foil negative electrode. An adhesive, UV-curable intermediate layer is adhered to the first layer on a first side of the intermediate layer and is adhered to the second layer on a second side of the intermediate layer. The intermediate layer includes a water-soluble electroactive material and a water-soluble viscosity-regulating polymer in an amount sufficient to render the intermediate layer adhesive. The intermediate layer also includes a water-insoluble polymer matrix having sufficient rigidity to prevent contact of the first layer and the second layer. A flexible package encases the first, second, and intermediate layers.