Learn how the integration of thin, printed batteries can help reduce costs in numerous applications, from R&D activities to full-scale production.
By Matt Ream
Supporting product development and innovation can be a tough challenge in a tight economy when manufacturing companies need to focus on reducing costs and retaining customers. Fortunately, there are technologies that can help manufacturers continue to bring new products to market quickly and with lower development and production expenses. Among these recently commercialized technologies are printed electronics and thin, printed batteries.
Innovative thin-battery design and production
Printed electronics is generally defined as the printing of electronic devices on common media such as paper, plastic, or textiles using standard printing processes. Low-cost, thin, flexible batteries are printed on a recyclable plastic PET base using carbon, zinc, and manganese dioxide. The anode material is a laminate of zinc foil or printed zinc, and the cathode material is a manganese dioxide paste mixed with carbon. After a piece of separator paper is placed atop the printed design, a couple of drops of electrolyte are added to start the battery’s reaction, and a top layer of PET is used to seal the battery cell. Power generation in the battery results from a chemical reaction between the electrolyte liquid and other materials.
While this process may sound complex, in actuality it can be done relatively quickly and cost-effectively. The batteries are manufactured using conventional, high-speed, roll-to-roll printing processes, which means they can be prototyped economically and mass produced quickly. This scalability factor makes it possible to achieve significant economies of scale as product development advances from pilot-test quantities to high-speed, high-volume production.
Thin, printed carbon-zinc batteries function as primary battery cells, which means they are not rechargeable. However, they are relatively low in cost, offer a broad range of capabilities, and may be safely stored in cold storage to slow the chemical reaction in the battery.
Awareness of the capabilities of low-voltage, printed batteries continues to expand around the globe, which has increased acceptance levels. Standard and customized batteries are currently being tested and deployed across diverse industry sectors. Users include designers and developers of battery-assisted RFID and sensor systems, powered cards, smart packaging and merchandising displays, consumer healthcare and cosmetic aids, and novelty products.
Following is a representative sampling of applications in which thin, printed, low-voltage carbon-zinc batteries can work.
Innovative thin-battery design and production
Printed electronics is generally defined as the printing of electronic devices on common media such as paper, plastic, or textiles using standard printing processes. Low-cost, thin, flexible batteries are printed on a recyclable plastic PET base using carbon, zinc, and manganese dioxide. The anode material is a laminate of zinc foil or printed zinc, and the cathode material is a manganese dioxide paste mixed with carbon. After a piece of separator paper is placed atop the printed design, a couple of drops of electrolyte are added to start the battery’s reaction, and a top layer of PET is used to seal the battery cell. Power generation in the battery results from a chemical reaction between the electrolyte liquid and other materials.
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