JP7018974B2 - Flexible battery as an integrated platform for wearable sensors and processing / transmitting devices - Google Patents

Description

Among the many applications, thin with high energy density with wearable devices, healthcare, cosmetics, wearable medical sensors and drug delivery devices, portable electronics, smart packaging, and recent enthusiastic development of RFID. The development of flexible batteries has become an essential challenge in providing adequate power to each device.

Depending on the device, these batteries should provide a potential that is not only suitable for current electronics (V range), but also has energy from μWh to kWh, to cover a wide range of applications. However, in addition to electrical parameters, these new applications also require the battery to be flexible, thin, stretchable, rollable, bendable, and foldable, and to cover small and large areas. And. These features are achieved in a typical battery design where the electrodes are printed on a current collector such as metal leaf, and for batteries enclosed in rigid enclosures such as coins, cylinders, or prismatic cells. It is difficult to do.

Nanomaterials are known to be extremely sensitive to their surroundings and are therefore new senses for a wide range of areas including environmental pollution, spatial exploration, homeland security, biology, and medicine. Materials and devices need to be developed. Among the applications of wearable sensors or devices, real-time monitoring of human physiology is of great importance. For this purpose, the technical requirements of wearable devices need to be combined with any mechanical properties that they are also comfortable, flexible, lightweight, small and washable. Therefore, new designs and materials are needed to provide battery power supply and mechanical support for the field of this rapidly emerging wearable device.

The present disclosure relates to a wearable device integrated with a flexible battery. In some embodiments, the present disclosure comprises a flexible battery and an electronic device attached to, printed, and / or embedded in the packaging layer of the flexible battery and powered by the flexible battery. With respect to wearable devices. According to some embodiments, the electronic device is selected from sensors, microprocessors, wireless communication / transmission devices, circuit boards, electronic devices, and mixtures thereof.

In some embodiments, the packaging layer of the flexible battery provides a support substrate for a wearable device or sensor. In some embodiments, the sensors are heart rate sensor, respiratory rate sensor, blood pressure sensor, blood oxygen sensor, body temperature sensor, muscle activity sensor, seizure event sensor, brain wave measurement (EEG) sensor, epilepsy onset sensor, brain wave sensor ( You can choose from ECG) sensors, myoelectric data (EMG) sensors, skin electrical activity (EDA) sensors, contaminant sensors, motion sensors, and mixtures thereof. In some embodiments, the transmitter is capable of transmitting a signal if one or more sensors register a threshold, eg, a low body temperature.

In some embodiments, the packaging layer is a pouch cell, which is an anode comprising an anode composite material having anode active material particles within a three-dimensional cross-linking network of carbon nanotubes and within a three-dimensional cross-linking network of carbon nanotubes. It comprises a cathode comprising a cathode composite material having cathode active material particles and a flexible separator film between the anode and the cathode. In some embodiments, the pouch cell comprises a polymer. In some embodiments, the flexible battery is encapsulated in a pouch cell in a flat or folded configuration, for example, the flexible battery can be folded more than once inside the packaging layer. According to some aspects, a method of making an electronic device having a flexible battery as an integrated platform for the electronic device is disclosed herein.

FIG. 3 shows a schematic diagram of a single cell (FIG. 1A) configuration of a battery according to some aspects of the present disclosure. FIG. 3 shows a schematic diagram of a multicell (FIG. 1B) configuration of a battery according to some aspects of the present disclosure.

Both schematically shown (FIGS. 2A and 2B), have a pouch cell in a flat (FIG. 2A) configuration, showing a pouch cell according to some aspects of the present disclosure. Both have a pouch cell in a rolled (FIG. 2B) configuration, shown schematically (FIG. 2A and FIG. 2B), showing a pouch cell according to some aspects of the present disclosure.

FIG. 3 shows a schematic diagram of a single cell (FIG. 3A) configuration of a battery according to another aspect of the present disclosure. FIG. 3B shows a schematic diagram of a multicell (FIG. 3B) configuration of a battery according to another aspect of the present disclosure.

FIG. 3 shows a schematic cross-sectional view of a preferred electrode layer structure according to some aspects of the present disclosure, having separator films on both sides (FIG. 4A). FIG. 3 shows a schematic cross-sectional view of a preferred electrode layer structure according to some aspects of the present disclosure, which has a separator membrane on only one side (FIG. 4B).

A battery according to some aspects of the present disclosure in a folded configuration is shown.

Shown is a wearable device having electronic components attached to, printed and / or embedded in the surface of the packaging material of a flexible battery according to some aspects of the present disclosure.

The present disclosure includes an anode containing a composite material having anode active material (graphite, silicon, etc.) particles in a three-dimensional crosslinked network of carbon nanotubes, and a composite material having cathode active material particles in a three-dimensional crosslinked network of carbon nanotubes. With respect to a flexible battery comprising a cathode comprising and a separator positioned between the anode and the cathode. In some embodiments, the battery does not include a current collector. In some embodiments, the cathode, anode, and separator are filled in the pouch cell. The enclosure of this pouch cell is suitably flexible. In some embodiments, the pouch cell may be a polymer pouch cell. In some embodiments, the flexible battery packaging material provides a substrate for mounting, printing, or embedding the required device. In some embodiments, the flexible battery is configured for use in the form of a wrist / ankle band, strap, or patch. According to some embodiments, the wearable device can be configured to be attached to an animal or human limb, torso, or head. In some embodiments, the data collected by the sensor is processed by an in-vehicle processor or transmitted wired or wirelessly to a mobile device for processing and display. In some embodiments, the mobile device is a smartphone.

In some embodiments, the one or more electronic devices are positioned inside the flexible packaging material, outside the flexible packaging material, or embedded within the flexible packaging material.

The electrodes in the battery may not be supported by a current collector foil such as aluminum for the cathode or copper at the anode and may not contain a binder that may crumble or peel off. Instead, the electrodes are self-supporting. Without being bound by any particular theory, the presence of carbon nanotube webs makes the electrodes self-supporting and flexible, which gives rise to flexible batteries. The batteries according to the present disclosure work well in rectangular pouch cells under a wide range of curvatures, turns, and folds (at angles greater than 180 °) along various battery axes.

As used herein, electrodes that are "flexible" can be curved without cracking or breaking. As will be known to those of skill in the art, flexibility may depend on one or more chemical and / or material factors, including, but not limited to, composition and degree of compression.

In some variations, the present disclosure is a flexible packaging material and a flexible battery positioned within the flexible packaging material, wherein the flexible battery comprises an electrode and the electrode is carbon. It relates to a wearable device comprising a flexible battery comprising a composite material containing active material particles within a three-dimensional crosslinked network of nanotubes and one or more electronic devices powered by the flexible battery.

As used herein, the term "about" is defined as being close to being understood by one of ordinary skill in the art. In one non-limiting embodiment, the term "about" is defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

In addition, the thickness of the free-standing electrode may be modified by pressing, which increases the overall thickness by about 4 times, about 3 times, about 2 times, about 1.5 times, about 1.1 times. , Or any range between them, etc., can reduce the overall thickness by as much as 5 times. For example, a freestanding electrode with a thickness of 100 μm may be pressed to a thickness of 50 μm (ie, the overall thickness is reduced by half), or a freestanding electrode with a thickness of 500 um may be pressed to a thickness of 100 μm (ie, reduced in half). , The overall thickness is reduced up to 5 times). In some embodiments, pressing reduces the overall thickness by half. In some embodiments, pressing reduces the overall thickness by about 1.1 to about 5 times. In some embodiments, pressing reduces the overall thickness by about 1.5 to about 3 times. The optimum degree and / or limit of pressure on a given material can be determined by one of ordinary skill in the art. Preferably, the pressing does not substantially destroy the active material particles / fragments, i.e., as a general guidance, 25% or less of the particles or fragments are damaged. The exact rate of acceptable particle damage may vary due to different formulations of different active materials and electrode complexes and will need to be determined by one of ordinary skill in the art in each case. For batteries with a liquid or gel electrolyte, preferably sufficient voids remain within the material after being pressed for access to the effective electrolyte, i.e. at least 50% of the surface of each particle or fragment of the active material (preferably). 100% of the surface) is wetted by the electrolyte. Additionally, the voids are suitably interconnected after pressing, i.e., there are no inaccessible voids. As a general guideline, the density of the pressed material should preferably be lower than the bulk density of the active material powder (higher, not the density of the active material, eg NMC (lithium nickel manganese cobalt oxidation). In the case of the product, LiNi _x Mn _{y Cobalt} O ₂ ) powder, the bulk density is about 2.35 g / cm ³ , while the density of NMC itself is> 3.5 g / cm ³ ). Pressing the electrode material to a density approaching or exceeding the bulk density of the active material powder can result in an electrode material that cracks easily and no longer needs to be flexible.

Pressing can improve flexibility, mechanical strength, and / or electrolyte accessibility in batteries according to aspects of the present disclosure. Pressing also corrects the density of the electrodes. Suitable methods and devices for pressing electrodes known in the art are incorporated herein by reference in their entirety, U.S. Patent Application No. 15/665, filed July 31, 2017. 171 is included in, but not limited to, those disclosed in the title "Self-Standing Electrodes and Methods for Making Thereof". According to aspects of the present disclosure, individual electrodes may be pressed, or the entire assembly of multiple electrodes separated by a separator may be collectively pressed with or without a pouch cell. good. In some embodiments, pressing reduces the overall thickness by about 1.1 to about 5 times. In some embodiments, pressing reduces the overall thickness by about 1.5 to about 3 times.

As is known to those of skill in the art, pressing or compression can improve electrical and / or mechanical contact between the battery tab and the complex, and can also mechanically make the complex stronger. can. However, excessive compression or pressing can impede the access of the electrolyte to the inner part of the electrode, complicating the movement of metal ions into and out of the electrode, thereby deteriorating the dynamic properties of the battery. Excessive compression can also lead to rigid and brittle electrodes, which can easily form cracks and collapses, which can reduce battery capacity or completely destroy it. Alternatively, too little compression leads to sufficient contact, mechanically weak electrode material, insufficient electrical contacts within the material (and thus lower conductivity of the material, and inefficiency from active material particles. (Current collection) and / or may not provide incomplete mechanical capture of active material particles in the nanotube network, which can be wasted by the electrolyte. Insufficient pressing also results in thicker electrodes that require more electrolyte to be completely moistened, thus reducing the energy storage density of the battery. In addition, excessive pressing can result in puncture of the separator membrane, which is not a desirable result. In addition, it may be desirable to adjust the distance between the rolls or rollers in the roll presser or calendar processing machine, and between the plates for flat plate pressing. Determining the optimum pressing thickness based on the desired properties of the electrode is within the knowledge of one of ordinary skill in the art. Suitable devices for pressing the electrodes and / or batteries of the present disclosure include, but are not limited to, roller mills and hydraulic pressing.

As used herein, "electrode active material" refers to a material that hosts a metal (eg, lithium) within an electrode. The term "electrode" refers to an electrical conductor in which ions and electrons are exchanged for electrolytes and external circuits. "Positive electrode" and "cathode" are used interchangeably herein to refer to an electrode having a higher electrode potential (ie, higher than a negative electrode) in an electrochemical cell. "Negative electrode" and "anode" are used interchangeably herein to refer to an electrode having a lower electrode potential (ie, lower than a positive electrode) in an electrochemical cell. Cathode reduction refers to the acquisition of a chemical species electron (s), and anode oxidation refers to the loss of a chemical species electron (s).

In some embodiments, a method of making a wearable integrated platform for an electronic device is disclosed herein, wherein the method provides a flexible battery with a packaging layer and one or more. Includes embedding an electronic device in a packaging layer, printing, and / or mounting, and electrically connecting one or more electronic devices to a flexible battery. In some embodiments, methods of making electronic devices are disclosed herein by printing, embedding, mounting, or combining electronic devices in flexible battery packaging. Includes assembling and powering the electronic device from the flexible battery with the flexible battery packaging to form the electronic device.

Metals in lithium metal oxides according to the present disclosure include, but are not limited to, one or more alkali metals, alkaline earth metals, transition metals, aluminum, or post-transition metals, and hydrates thereof. be able to. Non-limiting examples of lithium metal oxides include lithium oxides of Ni, Mn, Co, Al, Mg, Ti, and any mixture thereof. In an exemplary embodiment, the lithium metal oxide is a lithium nickel manganese cobalt oxide (LiNi _x Mn _y Co _z O ₂ , x + y + z = 1), such as Li (Ni, Mn, Co) O ₂ , Li—Ni. -Mn-Co-O, (LiNiMnCoO ₂ ). Lithium metal oxide powders can have particle sizes defined within about 1 nanometer to about 100 microns, or any integer or partial range between them. In a non-limiting example, the lithium metal oxide particles have an average particle size of about 1 μm to about 10 μm.

An "alkali metal" is a Group I metal of the Periodic Table of the Elements, such as lithium, sodium, potassium, rubidium, cesium, or francium.

An "alkaline earth metal" is a Group II metal of the Periodic Table of the Elements, such as beryllium, magnesium, calcium, strontium, barium, or radium.

A "transition metal" is a metal in the D block of the Periodic Table of the Elements, including lanthanides and actinides. Transition metals include, but are not limited to, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, lawrencium, palladium, silver, Cadmium, lantern, cerium, placeodim, neodym, promethium, samarium, europium, gadrinium, terbium, dysprosium, formium, erbium, turium, itterbium, lutetium, hafnium, tantalum, tungsten, renium, osmium, iridium, platinum, gold, mercury, Includes actinium, terbium, protatinium, uranium, neplanium, plutonium, americium, curium, berkelium, californium, einsteinium, fermium, mendelevium, nobelium, and lawrencium.

"Post-transition metals" include, but are not limited to, gallium, indium, tin, thallium, lead, bismuth, or polonium.

When used herein, the charge-discharge capacity of a battery in a curved, rolled, or folded configuration is measured, for example, by the output of a device connected to the battery, the charge of the battery. -If the discharge capacity is substantially the same as before being curved, rolled or folded, the battery "operates normally" in a curved, rolled or folded configuration. The bent, rolled, or folded capacity is "substantially" the original or flat charge-discharge capacity if it is within 75% of the original or flat charge-discharge capacity at 0.1 C rate. Is the same. " As is known to those of skill in the art, "C rate" (s), such as 0.1, 1, 10, 100, are known technical terms among those that affect the characteristics of the battery. As used herein, "1C rate" means that a constant discharge current discharges the entire battery for 1 hour, or a constant charge current charges the battery for 1 hour. As used herein, "0.1 C rate" means that the current is 10 times smaller, meaning that the battery is charged / discharged in 10 hours. In practice, first, the "theoretical capacity" of the battery at A ^* h (or mA ^* h) is calculated based on the amount of active material in the battery and the specific capacity of the material. Then divide by the desired number of hours (1 hour for 1C, 5 hours for 0.2C, 10 hours for 0.1C, 0.1 hours for 10C) and charge / discharge current. Is calculated. The charge or discharge capacity of the battery is then measured using this current, which is called the charge or discharge capacity at its C rate.

In some embodiments, the battery is in a single cell configuration. FIG. 1A shows a schematic diagram of the battery 100 according to the present disclosure in a single cell configuration. In some such embodiments, the first packaging layer 101 is adjacent to the anode layer 102, which is adjacent to the separator layer 103, which is adjacent to the cathode layer 104, and which is adjacent to the second packaging layer 101. The anode layer 102 and / or the cathode layer 104 may be configured to include a mounting point for the battery tab 106.

In some embodiments, the battery is in a multi-cell configuration. FIG. 1B shows a schematic diagram of the battery 110 according to the present disclosure in a multi-cell configuration. In some such embodiments, the plurality of alternating layers of the anode 102 and the cathode 104 are arranged between the separator layer 103 and the packaging layer 101. Each anode layer 102 and / or cathode layer 104 may be configured to include a mounting point for a battery tab. For the anode layer 102, the battery tab is preferably a copper tab or lead 105. For the cathode layer 104, the battery tab is preferably an aluminum tab or lead 106. In the multi-cell configuration, some electrodes in the inner portion of the multi-cell are in contact with the separator membranes 103 on both sides (FIGS. 1B, 3B). The number of electrode layers and separator layers in the multi-cell configuration is not particularly limited, and as indicated by the optional additional layer 111, the multi-cell configuration battery 110 has additional anodes, cathodes, than shown in FIG. 1B. And / or may contain a separator layer. The battery 110 may be similar to the battery 100 in some embodiments.

The electrodes according to the present disclosure can be manufactured by any suitable means known to those of skill in the art. For example, the anode and / or cathode refers to the methods and devices disclosed in US Patent Application No. 15 / 665,171, entitled "Self-Standing Electrodes and Methods for Making Theof," filed July 31, 2017. It may be prepared using. A method for making a self-supporting electrode with an embedded tab is described in US Patent Application No. 16 / 123,872, filed September 6, 2018, entitled "Method For Embedding A Battery Tab Attachment In A Self-Standing Electrode". Disclosed in "Without Patent Collector Or Binder". The method of making the tabbed configuration shown in the present disclosure is, among other things, the US Patent Application No. 16 / 123,935, entitled "Production Of Solly Carbon Nanotubes Supported Self-Standing," filed September 6, 2018. It is disclosed in "Electrodes For Flexible Li-Ion Batteries". Each disclosure of the aforementioned applications is expressly incorporated herein by reference. Suitable carbon nanotubes for use in the methods of the present disclosure include single-walled nanotubes, minority-walled nanotubes, and multi-walled nanotubes. In some embodiments, the carbon nanotubes are single-walled nanotubes. Minor-walled nanotubes and multi-walled nanotubes can be synthesized, characterized, co-deposited, and collected using any suitable method and apparatus known to those of skill in the art, including those used for single-walled nanotubes. can.

Suitable separator materials include those known to those of skill in the art for use between the battery anode and cathode, such as a membranous barrier or separator membrane, while providing a barrier between the anode and cathode. Allows the exchange of metal ions from one side to the other. Suitable separator materials include, but are not limited to, polypropylene, polyethylene, and composites thereof, as well as polymers such as PTFE. The separator membrane is permeable to metal ions, allowing it to move from the cathode side to the anode side and return during the charge-discharge cycle. However, the separator membrane is impermeable to the anode and cathode materials, preventing battery mixing, contact, and short circuits. The separator membrane also acts as an electrical insulator for the metal parts of the battery (lead, tabs, collectors, metal parts of the enclosure, etc.) that prevent contact and short circuit. The separator membrane also prevents the flow of electrolytes.

In some embodiments, the separator is a thin (15-25 μm) polymer membrane (three-layer complex: polypropylene) between two relatively thick (20-1000 μm) porous electrode sheets produced by our technique. -Polyethylene-Polypropylene, commercially available). The thin polymer membrane may be 15-25 μm thick. The two relatively thick porous electrode sheets can each independently have a thickness of 50-500 μm.

The polymer used in the polymer pouch cell protects the user from the electrochemical cell, for example, to protect the electrochemical cell from the external environment, or in the case of a flexible battery used in a wearable device. It may be any polymer suitable for use in an electrochemical cell for the purpose. As is known to those skilled in the art, a pouch cell refers to an external packaging material that holds electrodes and separators (s), and an internal electrolyte. Suitable materials are polyethylene (polyethylene or polypropylene coated aluminum: eg polyamide (JIS Z1714): 0.025 mm (+ -0.0025 mm), adhesive (polyurethane-polyurethane): 4-5 g / m2, aluminum foil. (JIS A8079, A8021): 0.040 mm (+ -0.004 mm), adhesive (urethane-free adhesive): 2-3 g / m2, polypropylene: 0.040 mm (+ -0.004 mm) including), PTFE , PDMS, etc., known to those of skill in the art. Batteries according to the present disclosure can be assembled using any suitable method, including those known to those of skill in the art.

According to the aspects of the present disclosure, the battery tab extends from the electrode, the body of each electrode, extends beyond the separator membrane and does not overlap the other electrode, or the separator membrane and the opposite electrode are cut. It can be attached to any of the main bodies of each electrode in the notch. Suitable battery tab materials and mounting methods include those known to those of skill in the art. It should be understood that the battery tabs disclosed herein are not current collectors.

In some embodiments, the battery according to the present disclosure is assembled by placing a separator between the fully prepared anode and the fully prepared cathode without further repressing. As used herein, the "fully prepared" anode or cathode is one that is pressed and attached to the tab. In some embodiments, the battery according to the embodiments of the present disclosure is assembled by placing a separator between the pre-pressed anode and the pre-pressed cathode and pressing them all together. As used herein, a "prepressed" electrode is pressed, but may or may not be attached to a tab, or is embedded within a tab attachment. It may be. In some embodiments, the battery can be assembled by placing a separator between one unpressed first electrode (anode or cathode) and the prepressed electrode (anode or cathode). The entire assembly can be pressed together.

Preferably, the concentration of carbon nanotubes on the surface of the electrode facing the separator is higher (5-100 wt% nanotubes) than in the electrode bulk (0.5-10 wt% nanotubes), while from the separator. The concentration of carbon nanotubes on the surface of the distant electrodes is lower than that in the bulk of the electrodes (FIG. 3) (0-1 wt% nanotubes). Composites containing more than about 5% nanotubes are very sticky and will adhere to separator membranes and stainless steel (typical materials from which rollers in roller mills are made), as well as many other materials. It will be considered by those skilled in the art. For example, composites containing 5% nanotubes, 95% NMC (lithium nickel manganese cobalt oxide, LiNi _x Mn _{y Coz} O ₂ ) (when newly created on the side) adhere very well to the rollers. It is difficult to separate from the rollers without tearing the composite. However, the same material "sprinkled" with NMC powder should not adhere to the rollers in any significant amount. These "boundary layers" may be 2-5 times thicker than the average size of the active material particles / fragments, for example, in the case of NMC particles used for cathodes, with increased or decreased nanotube content. An average diameter of "boundary layer" with a thickness of about 10 μm, 20-30 μm may be sufficient. According to aspects of the present disclosure, this distribution of carbon nanotubes on or within the electrode facilitates adhesion of the electrode to the separator film, while the rollers and other elements of the pressing device (pressed electrode and pressed). Reduces adhesion to batteries). This distribution shows that during the growth of the electrode material (eg, 100% active material aerosol at the beginning of synthesis, 97% active material aerosol, and 3% nanotube aerosol in most of the synthesis, and 100% nanotube at the end of synthesis. Aerosol), ratio of nanotube aerosol to active material aerosol (s) (s) (ie, the ratio of the weight of nanotubes deposited per unit time to the weight of active material deposited per unit time) It can be achieved by changing. For example, according to the present disclosure, a nanotube synthesis reactor can be configured to produce about 2 mg of aerosolized nanotubes (amount deposited on a frit / filter) per hour. In the same setting, the NMC feeder may be configured to aerosolize about 2 to 600 mg of NMC particles per hour (again, the amount deposited on the same filter). Therefore, depending on the setting of the NMC feeder, it is possible to deposit a material containing 50% nanotubes (2 mg + 2 mg) to about 0.3% nanotubes (2 mg + 600 mg). Operating only the nanotube reactor (NMC feeder off) produces 100% nanotube material, while operating only the NMC feeder (NMHz reactor off) produces 0% nanotube material (NMC powder). Will be done. Suitable methods for varying the ratio of nanotube aerosols and active nanotube aerosols (s) during growth are, but are not limited to, US Patent Application No. 15 / 665,171 filed July 31, 2017. , Includes those disclosed in the title "Self-Standing Electrodes and Methods for Making Thereof".

Batteries may be of any size, i.e., any length, width, and height. In some embodiments, the battery thickness is 0.01 mm to 10 mm. In some embodiments, the length and width are each independently from 0.1 mm to 10000 mm.

2A and 2B show batteries according to the present disclosure. The completed pouch battery cell contains a 3 x 4 cm electrode. The thickness of the battery is 3 mm. In a flat configuration (FIG. 2A), the battery 200 operates to power electronic devices and devices. After multiple bending cases at different angles and in different directions, the battery 200 can still power the electronic device. In the wound configuration (Fig. 2B). The battery 200 may be similar to the battery 100 in some embodiments.

In the case of the battery 300 having the configuration shown in FIG. 3A, all the electrodes in the multicell configuration shown in FIG. 3B (for example, the anode 102 and the cathode 104 in FIG. 3A) and the inner electrodes 102 and 104 of the battery 310 are on both sides. It is advantageous to have an increased nanotube content 402 on both sides of the electrode in contact with the separator membrane 103 (ie, on both sides of the anode 102, both in contact with the separator membrane 103 and on both sides of the cathode 104. Both of them come into contact with the separator film 103) (FIG. 4A). In FIG. 4A, the center of the electrode contains a bulk of electrode material 401 containing 0.5-10 wt% nanotubes. Moving outward from the center of the electrode towards the separator membrane 103, the band 402 contains an electrode material with an increased nanotube content, such as 5-100% by weight of the nanotubes. The band 402 is in contact with the separator film 103 on its outer edge, and the separator film 103 is in direction 405, away from the side facing the band 402 and facing towards the roller or presser during manufacturing. Extend to. The batteries 300 and 310 may be similar to the battery 100 in some embodiments.

The difference between FIGS. 3A-3B and 1A-1B is that an extra separator membrane layer 103 is added on both outer flanks of the cell (both single-cell or multi-cell configurations). Improves mechanical integrity and allows better sliding of the cell with respect to the packaging. This extra layer of separator membrane 103 can be wrapped around the assembled cell. All electrodes of the battery shown in FIGS. 3A and 3B (both single-cell or multi-cell configurations) are in the configuration shown in FIG. 4A, while the outer electrodes of the battery shown in FIGS. 1A-1B are. , Should be within the configuration shown in FIG. 4B. In FIG. 4B, the outer surface of the separator membrane 103 faces the roller or press in direction 405 and the inner surface faces the band 402 of the electrode, which has an increased nanotube content, such as 5-100 wt% nanotubes. Have. Continuing inward across the band 402, the opposite side of the band 402 faces a region of bulk electrode material 401 containing 0.5-10 wt% nanotubes. The opposite side of the region of the bulk electrode material 401 faces a region of reduced nanotube content 404, which in turn contains 0 to 1% by weight of nanotubes. Moving further inward, the opposite side of the region of reduced nanotube content 404 faces inward in direction 405 towards the roller or press.

Cell assemblies according to the present disclosure (ie, alternating layers of anodes, separators and cathodes in a single cell configuration, or separator layers in a multi-cell configuration, one or more anodes, one or more separators, and one or more cathodes). In the pouch cell, either flat (ie, as shown in FIGS. 1A, 1B, and 2A) or folded one or more times before being encapsulated in the pouch cell (as shown in FIG. 5). It may be enclosed in. In the pouch cell battery 500, the battery containing the layers of the separator film 103, the anode 102, the separator film 103, the cathodes 1 to 4, and the separator film 103 is at least once before being encapsulated by the pouch cell made of the packaging layer 101. It can be folded. Electrolyte 107 is also suitably included in the pouch cell during encapsulation. The anode layer 102 and the cathode layer 104 may each be configured to include attachment points for battery tabs. For the anode layer 102, the battery tab is preferably a copper tab or lead 105. For the cathode layer 104, the battery tab is preferably an aluminum tab or lead 106. The battery 500 may be similar to the battery 100 in some embodiments.

Encapsulation in a pouch cell, such as the packaging layer 101 after pre-folding, can increase battery capacity, but can also reduce battery flexibility. In the folded configuration, an additional separator membrane may be required to prevent the electrodes from coming into contact with each other (or preventing any of their electrical leads from coming into contact with each other). In some such embodiments, the separator membrane is such that the multicell configuration alternates as shown in FIGS. 3A-3B, partially: separator 103, anode 102, separator 103, cathode 104, separator 103. It may be beneficial to include one or two extra layers. Such an assembly not only simplifies the folded configuration shown in FIG. 5, but also mechanically makes the battery stronger, which causes additional bending, folding, winding, bending, and / or wear and tearing. More importantly, the battery assembly involves minimal movement of the cell components relative to each other, as it makes it possible to withstand and the added separator layer makes it easy to slide the cell assembly onto the pouch cell. Allows sliding as a whole for packaging / encapsulation, between bending, folding, bending, etc. The movement of such internal cell components relative to each other can adversely affect cell performance. This configuration for the electrode (cathode and / or anode) material preferably increases the nanotube concentration on both sides, i.e., on both sides of the electrode in contact with the separator membrane. As the concentration of nanotubes on the electrode surface increases, the electrodes adhere well to both separator membranes, whereby only the separator membrane (s) touch the rollers or other equipment, thus assembling the entire 5-layer cell assembly and / Or facilitate pressing. When only one extra separator membrane is used, the electrode material surface that is not in contact with or faces the separator membrane preferably has a reduced nanotube content on the surface that is not in contact with the separator membrane. ..

In one embodiment, the flexible batteries of the present disclosure provide not only a power source for a wearable sensor or device, but also a platform for the integration of electronic devices such as sensors. Specifically, the surface of the packaging layer 101 of the flexible battery is used as a substrate for mounting, printing, and / or embedding an electronic device. Examples of suitable electronic devices include various types of sensors, microprocessors, wireless communication devices / transmitting devices (eg, antennas), circuit boards, and other electronic devices (eg, accelerometers, gyroscopes). Examples of suitable sensors include heart rate, respiratory rate, blood pressure, blood oxygen saturation, body temperature, muscle activity, seizure events, electroencephalogram measurement (EEG), epilepsy onset, electroencephalogram (ECG), myoelectric data (EMG), and. Includes those for detecting skin electrical activity (EDA). Additional embodiments of suitable sensors include those for monitoring the concentration of contaminants and the movement of objects. In one embodiment, the wearable device integrated with the flexible battery has a wide range of applications including monitoring environmental pollution, space exploration, homeland security, biology, and medical care. One of the preferred uses of wearable sensors / devices is real-time monitoring of human physiological parameters.

FIG. 6 shows a wearable device comprising a flexible battery 2 and an integrated electronic device 1. The flexible battery 2 is similar to the battery 200 of FIG. 2B. Optionally shown, 3 and 4 can be attachments for power supply devices as conductive battery tabs. The electronic device 1 of FIG. 6 includes a plurality of sensors 5, a circuit board / electronic device 6, a microprocessor 7, and an antenna 8. Components 1-8 of FIG. 6 are for illustrative purposes only and are not intended to be limited to a single preferred embodiment. For example, the components 5-8 may be individually embedded within the electronic device 1 or integrated together in any useful combination to form a sensor complex for a particular purpose. .. The integration of microprocessors enables on-board processing of data collected by various types of sensors. Alternatively, the data collected by the sensor can be uploaded via the antenna to an APP running on a separate mobile processing device such as a smartphone. Mobile processing devices enable fast calculation and simultaneous display of collected data. Further, depending on the structure of the sensor complex, both in-vehicle processing and remote processing by the mobile device can be executed at the same time.

Compared to some popular commercially available wearable devices such as mobile watches, this wearable device integrated with a flexible battery shows a clear advantage in real-time monitoring of human physiology. Flexible batteries as substrates provide power directly to sensors and other electronic devices embedded in the packaging layer and do not require a separate power source. The flexible battery as a substrate further provides ample space for a large number of embedded sensors and other electronic devices that generate very large contact areas, while the wristwatch is a single spot. If it is not close to, it has a relatively limited space to integrate everything and the contact area of the sensor is also limited. More sensors with larger contact areas as indicated by this wearable device will result in more accurate and faster reading of physiological parameters. Flexible batteries can take many forms such as straps, wrist bands, and patches. Thus, the wearable device integrated with the flexible battery can be attached to human or animal limbs, such as wrist / ankle bands or straps, as needed, and the torso or head as straps or patches. Can be attached to. In this way, the wearable device may be placed in the most desirable location of the subject, such as an animal or human, in order to obtain more accurate and faster readings of physiological parameters.

The dimensions of the components 5-8 in FIG. 6 range from a few microns to a few millimeters. With an embedded sensor and a small footprint of electronic components, this wearable device integrated with a flexible battery is comfortable to wear, flexible, lightweight, compact, and washable.

The description herein uses embodiments to disclose the invention, including preferred embodiments, in which one of ordinary skill in the art will make and use any device or system and implement any incorporated method. It makes it possible to carry out the present invention including the above. The scope of claims of the present invention is defined by the scope of claims and may include other embodiments arising from those skilled in the art. Such other examples are within the scope of the claim if they have structural elements that are not different from the literal language of the claim, or if they contain equivalent structural elements that are not substantially different from the literal language of the claim. It is intended to be. Aspects from the various embodiments described, as well as other known equivalents for each such embodiment, have been mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques according to the principles of the present application. can do.

The embodiments described herein have been described in conjunction with the exemplary embodiments outlined above, but will vary, at least to those of skill in the art, whether known or currently unexpected. Alternatives, modifications, modifications, improvements, and / or substantial equivalents may be apparent. Therefore, the above exemplary embodiments are intended to be exemplary rather than limiting. Various changes may be made without departing from the spirit and scope of this disclosure. Accordingly, the present disclosure is intended to include all known or upcoming alternatives, modifications, modifications, improvements, and / or substantial equivalents.

According to some embodiments, a flexible battery assembly is disclosed herein, a flexible battery having a packaging layer, and a packaging layer such that the flexible battery powers an electronic device. It comprises an electronic device embedded, attached, and / or printed within. The flexible battery assembly can be configured to be wearable by the user. In a non-limiting example, the flexible battery may be in an operable shape for attachment to an animal or human limb, torso, or head. Flexible battery assemblies can be in the form of wrist bands, ankle bands, head bands, straps, headphones, shoes, patches, prostheses, clothing, hats, hearing aids, and combinations thereof. For example, electronic devices include sensors, processors, wireless communication / transmission devices, circuit boards, power generation devices (eg, solar cells, nanogenerators, thermoelectric generators, generators), electronic devices, GPS, displays, and combinations thereof. Can be included. In some embodiments, the electronic device may be attachable and removable to the packaging layer of the flexible battery. For example, the sensors include heart rate sensor, respiratory count sensor, blood pressure sensor, blood oxygen sensor, body temperature sensor, muscle activity sensor, seizure event sensor, brain wave measurement (EEG) sensor, epilepsy onset sensor, brain wave sensor (ECG) sensor, Myoelectric data (EMG) sensors, cutaneous electrical activity (EDA) sensors, contaminant sensors, motion sensors, and combinations thereof can be provided, the sensors can be operational to provide data, and the data , Sent from the electronic device. In some embodiments, the sensor may further comprise an emergency transmitter that communicates with one or more of the sensors, the emergency transmitter having one or more of the sensors a threshold measurement, eg, a seizure. When the event threshold, hypothermia threshold, or low heart rate threshold is reached, it can behave to send a signal.

In some embodiments, the flexible battery as an integrated platform for an electronic device provides an integrated platform for another battery.

Accordingly, "Claims" is not intended to be limited to the embodiments set forth herein, but is consistent with the entire scope of the "Claims" language and is singular. References to the elements of are intended to mean "one or more" rather than "unique" unless specifically stated. All structural and functional equivalents of the various aspects of the elements described throughout this disclosure that are known to or will be known to those of skill in the art are expressly incorporated herein by reference and ". It is intended to be included in the scope of claims. Moreover, nothing disclosed herein is intended to be made public, whether or not such disclosure is expressly stated in the "Claims". No claim element is to be construed as a means and a function unless the elements are explicitly listed using the phrase "means for".

Further, the term "example" means "as an example, instance, or illustration" herein. All embodiments described herein as "Examples" should not necessarily be construed as preferred or advantageous over other embodiments. Unless otherwise stated, the term "several" refers to one or more. Combinations such as "at least one of A, B, or C", "at least one of A, B, and C", and "A, B, C, or any combination thereof" are It may include any combination of A, B, and / or C and may include a multiple of A, a multiple of B, or a multiple of C. Specifically, "at least one of A, B, or C", "at least one of A, B, and C", and "A, B, C, or any combination thereof" and the like. The combination may be A only, B only, C only, A and B, A and C, B and C, or A and B and C, and any such combination may be of A, B, or C. It may contain one or more of the members, or a plurality of members. Nothing disclosed herein is intended to be made public, whether or not such disclosure is expressly stated in the "Claims".

The following examples are provided to provide those skilled in the art with complete disclosure and description of the methods of manufacture and use of the invention and are not intended to limit the scope of what the inventors consider to be inventions. It is not intended to represent that the following experiments are all or the only experiments performed. Efforts have been made to ensure accuracy for the numbers used (eg quantities, dimensions, etc.), but some experimental errors and deviations should be considered.

In addition, all references throughout this application, such as patent documents, including issued or granted patents or equivalents, publications of patent applications, and non-patent literature documents, or other material, are described herein. , Are incorporated herein by reference in their entirety, just as they are incorporated individually by reference.

It will be appreciated that various implementations of the above-disclosed and other features and functions or alternatives or variants thereof can preferably be combined with many other different systems or applications. Also, one of ordinary skill in the art may make various currently predicted or unexpected alternatives, modifications, modifications, or improvements that are intended to be covered by the appended claims.

New features that are believed to be characteristic of this disclosure are set forth in the appended claims. In the following description, similar parts are designated by the same reference numerals throughout the specification and drawings. The drawings are not necessarily drawn to scale and, for clarity and brevity, certain drawings may be shown in exaggerated or generalized form. However, the present disclosure itself, as well as its preferred embodiments, further objectives and advances, are best understood by reference to the following detailed description of the exemplary embodiments of the present disclosure, when read in conjunction with the accompanying drawings. Will be.

Claims (16)

Flexible battery assembly
A flexible battery with a packaging layer and
An electronic device, wherein the electronic device comprises an electronic device that is embedded in the packaging layer so that the flexible battery provides power to the electronic device. assembly. The flexible battery assembly according to claim 1, wherein the flexible battery assembly is configured to be wearable by the user. The flexible battery assembly according to claim 1, wherein the electronic device includes a sensor, a processor, a wireless communication / transmission device, a circuit board, an electronic device, a GPS, a display, and a combination thereof. The sensors include heart rate sensor, respiratory rate sensor, blood pressure sensor, blood oxygen sensor, body temperature sensor, muscle activity sensor, seizure event sensor, brain wave measurement (EEG) sensor, epilepsy onset sensor, brain wave sensor (ECG) sensor, and myoelectricity. The flexible battery assembly according to claim 3, comprising a data (EMG) sensor, a skin electrical activity (EDA) sensor, a contaminant sensor, a motion sensor, and a combination thereof. The flexible battery according to claim 2, wherein the flexible battery is in the form of a wrist band, ankle band, head band, strap, headphones, shoes, patches, clothing, a hat, a hearing aid, and a combination thereof. assembly. The flexible battery assembly according to claim 2, wherein the flexible battery is in a shape that can be operated so as to be attached to an animal or human limb, torso, or head. The flexible battery assembly of claim 3, wherein the sensor is operable to provide data, the data being transmitted from the electronic device. Further equipped with an emergency transmitter that communicates with one or more of the sensors, the emergency transmitter can operate to transmit a signal when one or more of the sensors reaches a threshold measurement. The flexible battery assembly according to claim 4. The flexible battery assembly according to claim 1, wherein the electronic device comprises a power generation device. The flexible battery assembly according to claim 9, wherein the power generation device is a solar cell, a nanogenerator, a thermoelectric generator, a generator, or a combination thereof. The flexible battery assembly of claim 1, wherein the additional electronic device is attachable and removable to the packaging layer of the flexible battery. The packaging layer is a pouch cell, and the pouch cell is
An anode containing an anode composite with anode active material particles within a three-dimensional crosslinked network of carbon nanotubes,
A cathode containing a cathode composite with cathode active material particles within a three-dimensional crosslinked network of carbon nanotubes,
The flexible battery assembly according to claim 1, comprising a flexible separator membrane between the anode and the cathode. The flexible battery assembly according to claim 1, wherein the cell assembly of the flexible battery is folded inside the packaging layer. A method of making a wearable integrated platform for electronic devices to provide a flexible battery with a packaging layer.
Embedding one or more electronic devices in the packaging layer
A method comprising electrically connecting the one or more electronic devices to the flexible battery. A method of making electronic devices
Assembling electronic devices by methods, including embedding in a flexible battery packaging layer ,
A method comprising supplying power to an electronic device from a flexible battery comprising the flexible battery packaging layer to form the electronic device. 15. The method of claim 15, wherein the electronic device, the flexible battery packaging layer , and the flexible battery are wearable by the user.

Images