Printed Flexible Electrochemical Cell Manufacturing via Pouch Sealing
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Solution Overview
Problem
There is a need for an economical and efficient method to mass-produce thin, low-power batteries suitable for modern applications, as existing approaches have been costly and inefficient in producing batteries that are both thin and capable of meeting the reduced power requirements of contemporary devices.
Innovation Solution
A method involving a substrate with multiple layers, where electrochemical layers and an electrolyte layer are printed and sealed within a pouch formed by folding the substrate, allowing for the mass production of thin, flexible batteries with improved conductivity and low-temperature performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery manufacturing methods are used, then battery performance and reliability are maintained, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple manufacturing steps (substrate preparation, electrochemical layer deposition, electrolyte filling, and sealing) into a single integrated pouch-filling process. The pouch structure is formed by folding a single substrate sheet, and all components are assembled within this pouch in one continuous operation, eliminating the need for separate manufacturing steps and reducing overall production time and cost.
Solution Approach 2:
The substrate is pre-formed into a pouch structure with folded edges and sealed sides before the actual battery components are assembled. This preliminary pouch formation allows for efficient subsequent filling and assembly operations, as the containment structure is already in place, reducing the complexity of the manufacturing process.
2Length of moving object
If thin battery design is implemented, then flexibility and modern application suitability are improved, but manufacturing complexity increases
Solution Approach 1:
The battery is segmented into distinct functional layers (electrochemical layers, electrolyte layer, separator) that are deposited in a sequential printing process. This segmentation allows each layer to be optimized independently while maintaining overall thinness, and the printed deposition method enables precise control over layer thickness and composition without requiring complex manufacturing equipment.
Solution Approach 2:
The patent uses a flexible pouch structure formed from a thin substrate that can be folded and sealed to create the battery containment. This flexible shell approach replaces rigid battery casings, enabling thin battery design while simplifying the manufacturing process through the pouch-filling method that is well-suited for flexible material handling.
3Productivity
If printed electrochemical layers are used, then manufacturing cost decreases and production efficiency increases, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical deposition methods (such as sputtering or vapor deposition) with a printing-based deposition system. The printing process uses inkjet or similar printing technology to deposit electrochemical layers as liquid or paste materials that are then cured or dried. This substitution enables lower-cost equipment, higher production speeds, and the ability to print complex patterns directly, while the printing process parameters can be precisely controlled to achieve the required layer precision.
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
This approach enables the production of thin, flexible batteries that are cost-effective, reliable across various temperatures, and suitable for low-power applications, with enhanced low-temperature performance and ease of assembly, making them suitable for use in devices such as RFID tags and other transient electrically operated devices.
Implementation Method 1
an electrolyte layer substantially covering and in electrical contact with both the first electrochemical layer and the second electrochemical layer
Data Source
AI summary
A thin printed flexible electrochemical cell with a high moisture and oxygen barrier polymer film sealed and folded package featuring a printed cathode deposited on a highly conductive carbon printed cathode collector with a zinc foil anode or printed anode placed adjacent to the cathode. After the cell components are added to the special laminated polymer substrate, the web is processed automatically on a modified high-speed commercial horizontal pouch filling machine to complete the cell assembly process. In this process a starch coated paper separator layer may be inserted over the anode and the cathode, and then the aqueous electrolyte solution is added to the cell. To complete the process, all four edges of the cell are heat sealed to confine the cell components within the cell cavity and each cell is trimmed off the continuous web.