Sintered Biodegradable Sealing Layer for Moisture-Stable Batteries

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Solution Overview

Problem

Conventional batteries are not environmentally friendly and lack biodegradability, leading to toxic waste, and existing adhesives and sealants are non-biodegradable, making it challenging to create a robust, biodegradable sealing layer for electrochemical devices like batteries.

Innovation Solution

A biodegradable sintered sealing layer composition using poly(ε-caprolactone) (PCL) or polylactic acid (PLA) with an emulsifying additive like silicon dioxide, sintered between substrates to form a moisture barrier, which is applied using selective laser sintering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional adhesives and sealants are used to create a robust sealing layer, then the sealing performance and moisture barrier are improved, but the biodegradability and environmental friendliness deteriorate

Engineering Contradiction:

Improvesealing performanceVSAvoidnon-biodegradability

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameters by using biodegradable polymers (PLA, PCL) with specific glass transition temperatures and melting points, combined with inorganic fillers in controlled amounts, to achieve both sealing performance and biodegradability. The composition parameters are optimized to balance mechanical properties with environmental compatibility

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite sealing layer combining biodegradable organic polymers (PLA, PCL) with inorganic fillers (silica, alumina, calcium carbonate). This composite structure provides both the mechanical strength needed for sealing and the biodegradability required for environmental friendliness, resolving the contradiction between durability and biodegradability

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If all-printed processes are used to manufacture batteries, then the manufacturing cost and complexity are reduced, but the sealing layer quality and moisture barrier fidelity deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsealing layer fidelity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical adhesive application methods with a printing-based deposition process followed by thermal sintering. The sealing layer composition is deposited as a slurry or paste and then sintered to form a robust seal, eliminating the need for separate adhesive application steps while maintaining high sealing quality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transitions during the sintering process, where the deposited sealing layer composition undergoes thermal processing to transform from a slurry/paste state to a solid, robust sealing layer. This phase transition enables the formation of high-quality seals through a simplified printing process, achieving both ease of manufacture and manufacturing precision

Inventive Principle:

Principle #36Phase transitions

3Adaptability or versatility

If thin film printed batteries are used, then the flexibility and cost are improved, but the moisture retention and electrolyte activity maintenance deteriorate

Engineering Contradiction:

ImproveflexibilityVSAvoidmoisture retention

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs a thin film sealing layer that conforms to the flexible structure of printed batteries. The sealing layer is deposited and sintered to create a moisture barrier that maintains flexibility while preventing electrolyte drying, thus preserving both adaptability and reliability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing layer acts as an intermediary barrier between the internal battery components and the external environment. It selectively prevents moisture loss while maintaining electrolyte activity, mediating between the need for flexibility in thin-film batteries and the requirement for reliable moisture retention

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides a biodegradable sealing layer that maintains moisture integrity and ensures the electrochemical device's functionality while being environmentally friendly, addressing the need for compostable batteries.

Implementation Method 1

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

The sintered sealing layer composition may include a biodegradable polymer and an emulsifying additive. The emulsifying additive may include silicon dioxide.

Methodology Applied

Scientific EffectEmulsification: Emulsion

Data Source

PatentUS12500298B2Sealing layer for biodegradable electrochemical device and methods thereof

Publication Date: 2025.12.16 XEROX CORP

AI summary

Examples of the present disclosure include an electrochemical device. The electrochemical device includes a first substrate layer. The electrochemical device also includes an anode disposed upon the first substrate layer. The electrochemical device also includes a second substrate layer. The electrochemical device also includes a cathode disposed upon the second substrate layer. The electrochemical device also includes an electrolyte composition disposed between and in contact with the anode and the cathode. The electrochemical device also includes a sintered sealing layer composition disposed between the first substrate layer and the second substrate layer. A sintered sealing layer composition and methods for producing are also disclosed.