Printable Flexible Battery Structure for Bend-Stable Performance
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Solution Overview
Problem
Existing batteries are inflexible, bulky, and unsuitable for novel design applications due to their cylindrical or cuboid shapes, and current technologies fail to produce fully printable, highly flexible batteries with performance comparable to standard batteries.
Innovation Solution
A fully printable battery is fabricated using a roll-to-roll process on a flexible substrate with printed electrodes and electrolyte, allowing for customizable shapes and sizes, maintaining flexibility and electrochemical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional rigid battery construction is used, then structural strength is maintained, but flexibility is lost
Solution Approach 1:
The patent employs flexible substrates (polymer films) instead of rigid metal foils and plastic substrates to construct the battery electrodes and packaging. This allows the battery to be rolled or folded easily while maintaining structural integrity, directly resolving the contradiction between flexibility and structural strength.
Solution Approach 2:
The battery uses composite material construction with polymer substrates, printed electrodes, and gel electrolytes. This composite approach enables the battery to achieve both flexibility and adequate structural strength, as the polymer materials provide flexibility while the layered composite structure maintains integrity during flexing.
2Ease of operation
If flexible materials are used to enable bending, then flexibility is improved, but capacity and voltage decrease when flexed
Solution Approach 1:
The use of flexible polymer substrates and gel electrolytes allows the battery to maintain its electrochemical performance during flexing. The gel electrolyte specifically prevents leakage and maintains ionic conductivity even when the battery is bent or folded, preserving capacity and voltage.
Solution Approach 2:
The patent employs a separator layer and adhesive sealing between electrode layers to prevent damage during flexing. This protective construction prevents electrode delamination and short circuits that would otherwise occur when flexible batteries are bent, maintaining reliable electrochemical performance.
3Weight of moving object
If metal foils and plastic substrates are used for construction, then structural integrity is maintained, but flexibility and weight are compromised
Solution Approach 1:
The patent replaces heavy metal foils and rigid plastic substrates with thin flexible polymer films for substrate construction. This significantly reduces the battery weight while the multi-layer polymer composite structure maintains adequate structural integrity through proper layering and adhesive bonding.
Solution Approach 2:
The composite construction using multiple polymer layers with different functions (substrate, electrode support, separator, packaging) creates a lightweight yet structurally sound battery. Each layer contributes specific properties that collectively provide both weight reduction and structural integrity.
4Adaptability or versatility
If printed materials are used to achieve flexibility and customization, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs a universal printing process that can manufacture batteries in any shape, size, or configuration using the same basic methodology. The print head can deposit electrodes, electrolytes, and packaging materials in various patterns, enabling customization without requiring different manufacturing equipment or processes.
Solution Approach 2:
The manufacturing process allows easy adjustment of battery parameters such as capacity, voltage, shape, and size by modifying printing parameters (ink deposition amount, pattern, layer thickness) rather than changing the fundamental manufacturing process. This enables high adaptability with relatively simple manufacturing control.
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 batteries that are lightweight, highly flexible, and maintain electrochemical performance even when stretched or bent, suitable for high-capacity energy storage systems and wearable devices.
Implementation Method 1
The flexible battery and components may be fabricated using conventional printing techniques... The flexible battery and components may be fabricated using conventional printing techniques including, but not limited to, screen printing, flexographic printing, stencil printing, slot dye-coating, bar coating and rotogravure printing
Implementation Method 2
A battery is capable of producing electricity through electrochemical reactions between its two electrodes (anode and cathode) in the presence of an electrolyte
Data Source
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AI summary
A method of fabricating a flexible battery comprises forming a first substrate on a first release liner, forming at least one current collector layer on each of the first and second substrate, forming an anode side of the battery by forming an anode on the current collector of the first substrate, forming a cathode side of the battery by forming a cathode on the current collector of the second substrate, depositing electrolyte on one or both of the anode and cathode, adhering and sealing the anode side and cathode side together such that the anode and cathode face one another with the electrolyte In between, and removing the flexible battery from the release liners. The battery may be a primary battery or a secondary battery. The method may be implemented using a roll-to-roll process.