Stretchable Printed Battery With Elastomer Substrate

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Solution Overview

Problem

Conventional batteries are confined to non-deformable solid containers, limiting their usability due to restricted deformation, which hinders their application in flexible electronic devices.

Innovation Solution

A stretchable battery is developed using a layered structure comprising a first current collector, cathode, solid electrolyte, anode, and second current collector, embedded in an elastomer film, allowing for non-linear patterning and integration with conductive traces, manufactured through printing processes like stencil/screen printing, inkjet, or aerosol jet techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If conventional batteries are made with rigid shell bodies, then structural stability is improved, but flexibility and deformability deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidflexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the conventional rigid shell body with a flexible substrate that can be stretched and deformed. The battery components (electrodes, electrolyte, current collectors) are printed directly onto this flexible substrate, allowing the entire battery structure to bend and stretch without breaking, thus achieving both structural stability and flexibility.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical state of the electrolyte from liquid to solid, and modifies the mechanical properties of the battery components by using printed thin films and layers. This parameter change allows the battery to maintain its structural integrity while being flexible and stretchable, resolving the contradiction between stability and adaptability.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If batteries are confined in non-deformable containers, then manufacturing simplicity is improved, but application versatility deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidapplication versatility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent uses flexible substrates and thin film structures instead of rigid containers, enabling the battery to be integrated into flexible and wearable electronic devices while maintaining ease of manufacturing through printing processes.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible battery structure can be applied to multiple types of devices including wearable electronics, flexible displays, and deformable devices, making it universally applicable across different product categories while being manufactured using the same printing-based process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If solid electrolyte layers cover entire electrode surfaces, then short circuit prevention is improved, but manufacturing complexity deteriorates

Engineering Contradiction:

Improveshort circuit preventionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the electrolyte layer with the electrode structure by printing the solid electrolyte to cover the entire surface of each electrode, including the edges. This merging of functions ensures complete isolation between adjacent electrodes while using the same printing process for all layers, reducing manufacturing complexity despite the comprehensive coverage.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10003087B1Stretchable printed battery and methods of making

Publication Date: 2018.06.19 FLEXTRONICS AP LLC

AI summary

A stretchable battery and the method of manufacturing the same. The stretchable battery can be manufactured by using a printing process. The construction of the stretchable battery can comprise a first layer of an elastomer film, a first current collector layer, a layer of cathode, a separating layer, a layer of anode, and a second current collector layer. Metal traces can be used to couple with the first and/or the second current collector layers.