KR102363780B1 - Flexible battery as an integration platform for wearable sensors and processing/transmitting devices - Google Patents

Abstract

The present invention relates to a device integrated with a flexible battery, which may be wearable and may provide an integrated platform for a variety of electronic devices.

Description

FLEXIBLE BATTERY AS AN INTEGRATION PLATFORM FOR WEARABLE SENSORS AND PROCESSING/TRANSMITTING DEVICES

With the recent intensive development of wearable devices, healthcare, cosmetics, wearable medical sensors and drug delivery devices, portable electronics, smart packaging, and RFID, among other applications, high energy density thin flexible batteries (Flexible battery) has become an essential task to provide appropriate power to each device.

Depending on the device, these batteries must not only provide a suitable potential (V-range) for current electronic devices, but also must possess energy from μWh to kWh to cover a wide range of applications. However, these new applications, in addition to electrical parameters, are that batteries are also flexible, thin, stretchable, rollable, bendable, foldable, microscopic and It is necessary to cover a large area. These characteristics are important in typical battery designs where the electrodes are printed on a current collector such as a metal foil, and for batteries encapsulated in a rigid enclosure such as a coin, cylindrical or prismatic cell. difficult to achieve

Nanomaterials are known to be extremely sensitive to their surroundings, so there is a need to develop novel sensing materials and devices for a wide range of fields including environmental pollution, space exploration, homeland security, biology and medicine. Among applications of wearable sensors or devices, real-time monitoring of human physiological state is most important. For this purpose, it is necessary to combine the technical requirements of the wearable device with its mechanical properties, for example that the wearable device must also be comfortable, flexible, lightweight, compact, washable, etc. have. Accordingly, there is a need for new designs and materials for batteries that provide mechanical support and power in this fast emerging field of wearable devices.

The present invention relates to a wearable device integrated with a flexible battery. In some embodiments, the present invention provides a flexible battery; and an electronic device attached to, printed on, and/or embedded in a packaging layer of the flexible battery and powered by the flexible battery. According to some aspects, the electronic device is selected from sensors, microprocessors, wireless communication/transmission devices, circuit boards, electronic equipment, and combinations thereof.

In some aspects, the packaging layer of a flexible battery provides a supporting substrate for a wearable device or for a sensor. In some embodiments, the sensors are a heart rate sensor, a respiratory rate sensor, a blood pressure sensor, a blood oxygen sensor, a body temperature sensor, a muscle activity sensor, a seizure event sensor, an EEG sensor, an epileptic crisis. crisis) sensor, electroencephalogram (ECG) sensor, electromyography data (EMG) sensor, electrodermal activity (EDA) sensor, contaminant sensor, movement sensor, and combinations thereof. In some embodiments, the transmitter may send a signal when one or more sensors record a threshold, eg, a low body temperature.

In some embodiments, the packaging layer is a pouch cell, the pouch cell comprising: an anode comprising an anode composite material having anode active material particles within a three-dimensional cross-linked network of carbon nanotubes; a cathode comprising a cathode composite material having particles of cathode active material within a three-dimensional cross-linked network of carbon nanotubes; and a flexible separator membrane between the anode and the cathode. In some aspects, the pouch cell comprises a polymer. In some aspects, the flexible battery is encapsulated within a pouch cell in a flat or folded configuration, eg, the flexible battery can be folded one or more times within the packaging layer. According to some aspects, disclosed herein is a method of manufacturing an electronic device having a flexible battery as an integration platform for the electronic device.

Novel features believed to be characteristic of the invention are set forth in the appended claims. In the following description, like parts are denoted by like reference numerals, respectively, throughout this specification and drawings. The drawings are not necessarily drawn to scale, and certain drawings may be shown in exaggerated or generalized form for clarity and brevity. However, the invention itself, as well as its preferred modes of use, further objects and advances, will be best understood by reference to the following detailed description of exemplary aspects of the invention when read in conjunction with the accompanying drawings.
1A and 1B show schematic diagrams of a single-cell ( FIG. 1A ) configuration and a multi-cell ( FIG. 1B ) configuration of a battery in accordance with some aspects of the present disclosure.
2A and 2B illustrate a pouch battery in accordance with some aspects of the present invention, in which the pouch battery is schematically shown in both a flat configuration ( FIG. 2A ) and a rolled configuration ( FIG. 2B ) schematically ( FIGS. 2A and 2B ). .
3A and 3B show schematic diagrams of a single cell (FIG. 3A) configuration and a multiple cell (FIG. 3B) configuration of a battery according to another aspect of the present invention.
4A and 4B show schematic cross-sections of preferred electrode layer structures, according to some aspects of the present invention, with separator films on both sides ( FIG. 4A ) or on only one side ( FIG. 4B ).
5 illustrates a battery in accordance with some aspects of the present invention in a collapsed configuration.
6 illustrates a wearable device having electronic components attached to, printed on, and/or embedded on the surface of a packaging material of a flexible battery in accordance with some aspects of the present disclosure.

The present invention relates to an anode comprising a composite material having particles of anode active material (graphite, silicon, etc.) within a three-dimensional cross-linked network of carbon nanotubes; a cathode comprising a composite material having particles of the cathode active material within a three-dimensional cross-linked network of carbon nanotubes; and a separator positioned between the anode and the cathode. In some aspects, the battery has no current collector. In some aspects, the cathode, anode, and separator are packed within a pouch cell. Such pouch cell enclosures are suitably flexible. In some aspects, the pouch cell may be a polymer pouch cell. In some aspects, the packaging material of a flexible battery provides a substrate for attaching, printing, or embedding the necessary devices. In some aspects, the flexible battery is configured for use in the form of a wrist/ankle band, strap, or patch. According to some aspects, the wearable device may be configured to attach to a limb, torso, or head of an animal or human. In some aspects, data collected by a sensor is processed by an onboard processor or transmitted wired or wirelessly to a mobile device for processing and display. In some aspects, the mobile device is a smartphone.

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

The electrodes in the battery are not supported by a current collector foil, such as aluminum for the cathode or copper for the anode, and may not contain a binder that can flake or peel. Instead, the electrodes are self-standing. Without wishing to be bound by any particular theory, the presence of a carbon nanotube web makes the electrode freestanding and flexible; The flexible electrode allows a flexible battery to be created. Batteries according to the present invention operate successfully in rectangular pouch cells under a wide range of bending, winding, and folding (angles greater than 180°) along various battery axes.

As used herein, an electrode that is “flexible” can be bent without cracking or breaking. As is known to those skilled 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 invention provides a flexible packaging material; A flexible battery positioned within a flexible packaging material, the flexible battery comprising an electrode, the electrode comprising a composite material comprising particles of active material within a three-dimensional cross-linked network of carbon nanotubes; and one or more electronic devices powered by a flexible battery.

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

Also, the thickness of the freestanding electrode can be changed by pressing, which increases the overall thickness by 5 times, for example by about 4 times, by about 3 times, by about half, by about 1.5 times, by about 1.1 times. It can be reduced by a factor of, or anywhere in between. For example, a stand-alone electrode 100 um thick can be pressed to a thickness of 50 um (i.e., the overall thickness is reduced by half), or a free-standing electrode 500 um thick can be pressed to a thickness of 100 um ( i.e. the overall thickness is reduced by a factor of 5). In some aspects, pressing reduces the overall thickness by half. In some aspects, pressing reduces the overall thickness by about 1.1 times to about 5 times. In some aspects, pressing reduces the overall thickness by about 1.5 times to about 3 times. The optimal degree and/or limit of pressing for a given material can be determined by one of ordinary skill in the art. Suitably, pressing does not substantially destroy the active material particles/flakes, ie, as a general guideline, no more than 25% of the particles or flakes are damaged. The exact percentage of acceptable particle damage may vary for different active materials and for different formulations of electrode composites, and in each case needs to be determined by the person skilled in the art. For batteries with liquid or gel electrolytes, suitably sufficient voids remain in the material after pressing for efficient electrolyte access, i.e. at least 50% of the surface of each particle or flake of active material (preferably, 100% of the surface) is wetted by the electrolyte. Additionally, the pores are suitably still interconnected after pressing, ie there are no entrapped inaccessible pores. As a general guideline, the density of the pressed material is suitably the bulk density of the active material powder (not the density of the active material, which is higher; e.g., NMC (Lithium Nickel Manganese Cobalt Oxide, LiNi _x Mn _y Co _z O ₂ ) For powder, the bulk density is about 2.35 g/cm 3 , whereas the density of NMC itself is greater than 3.5 g/cm 3 ). Pressing the electrode material to a density approaching or exceeding the bulk density of the active material powder may result in the electrode material being easily cracked and no longer flexible.

Pressing may improve flexibility, mechanical strength, and/or electrolyte accessibility in batteries according to aspects of the present invention. Pressing also changes the density of the electrode. Methods and apparatus suitable for pressing electrodes are known in the art and entitled "Freestanding Electrodes and Methods of Making Same", filed July 31, 2017, which is incorporated herein by reference in its entirety. Self-Standing Electrodes and Methods for Making Thereof, U.S. Patent Application Serial No. 15/665,171. In accordance with aspects of the present invention, individual electrodes may be pressed, or an entire assembly of a plurality of electrodes separated by a separator, may be collectively pressed, with or without pouch cells present. In some aspects, pressing reduces the overall thickness by about 1.1 to about 5 times. In some aspects, pressing reduces the overall thickness by about 1.5-fold to about 3-fold.

As is known to those skilled in the art, pressing or compressing may improve electrical and/or mechanical contact between the battery tab and the composite, which may also make the composite mechanically stronger. However, too much compression or pressing can impede electrolyte access to the inner portion of the electrode and complicate the movement of metal ions in and out of the electrode, thereby deteriorating the dynamic properties of the battery. Too much compression also results in rigid and brittle electrodes that crack easily and disintegrate; This can reduce the battery capacity or destroy it completely. Alternatively, too little compression does not provide sufficient contact so that the electrode material is mechanically weak, insufficient electrical contact in the material (and thus lower electrical conductivity of the material and inefficient current collection from the active material particles), and/ or incomplete mechanical entrapment of the active material particles within the nanotube network (the active material particles may be washed away by the electrolyte). Insufficient pressing can also result in a thicker electrode, requiring more electrolyte to fully wet it, thus reducing the energy storage density of the battery. Also, excessive pressing can cause perforation in the separator film; This is not a desirable result. It may also be desirable to adjust the distance between the rolls or rollers in a rolling press or calendaring machine or the distance between the plates in a platen press. It is within the knowledge of those skilled in the art to determine the optimum pressing thickness based on the desired properties of the electrode. Apparatus suitable for pressing the electrodes and/or batteries of the present invention include, but are not limited to, roller mills and hydraulic presses.

As used herein, “electrode active material” refers to a material that hosts a metal (eg, lithium) in an electrode. The term “electrode” refers to an electrical conductor in which ions and electrons are exchanged with an electrolyte and an external circuit. “Anode” and “cathode” are used synonymously in this description and refer to an electrode having a higher (ie, higher than negative electrode) electrode potential in an electrochemical cell. "Cathode" and "anode" are used synonymously in this description and refer to an electrode having a lower (ie, lower than anode) electrode potential in an electrochemical cell. Cathodic reduction refers to the species gaining electron(s), and anodic oxidation refers to the loss of electron(s) to the species.

According to some aspects, disclosed herein is a method of manufacturing a wearable integrated platform for an electronic device, the method comprising: providing a flexible battery having a packaging layer; embedding one or more electronic devices in, printing on, and/or attaching one or more electronic devices to the packaging layer; and electrically connecting the one or more electronic devices to the flexible battery. In some embodiments, disclosed herein is a method of manufacturing an electronic device, the method comprising printing on flexible battery packaging, embedding within the flexible battery packaging, attaching to the flexible battery packaging, or a combination thereof. assembling an electronic device by a method comprising; and providing power to the electronic device from the flexible battery comprising the flexible battery packaging to form the electronic device.

The metal in the lithium metal oxide according to the present invention may include, but is not limited to, one or more alkali metals, alkaline earth metals, transition metals, aluminum, or post-transition metals, and hydrates thereof. Non-limiting examples of lithium metal oxides include lithiated oxides of Ni, Mn, Co, Al, Mg, Ti, and any mixtures thereof. In an illustrative example, lithium metal oxide is 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 ). The lithium metal oxide powder may have a particle size defined within the range of about 1 nanometer to about 100 micrometers, or any integer or subrange therebetween. In a non-limiting example, the lithium metal oxide particles have an average particle size of from about 1 μm to about 10 μm.

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

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

A “transition metal” is a metal of the d-block of the Periodic Table of the Elements, including the lanthanide and actinide series. Transition metals include scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, lanthanum, cerium, praseodymium, Neodymium, Promethium, Samarium, Europium, Gadolinium, Terbium, Dysprosium, Holmium, Erbium, Thulium, Ytterbium, Lutetium, Hafnium, Tantalum, Tungsten, Rhenium, Osmium, Iridium, Platinum, Gold, Mercury, Actinium, Thorium, Protactinium, uranium, neptunium, plutonium, americium, curium, berkeletium, californium, einsteinium, fermium, mendelebium, nobelium, and Laurentium.

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

As used herein, the charge-discharge capacity of a battery in a bent, rolled, or collapsed configuration, e.g., as measured by the output of a device connected to the battery, before bending, winding, or folding ( That is, a battery "works successfully" in a bent, wound, or collapsed configuration if substantially equal to the charge-discharge capacity of the battery (that is, its original or flat case capacity). The capacity when bent, rolled, or folded is equal to the charge-discharge capacity in the original or flat case and "substantially" if it is within 75% of the original or flat case charge-discharge capacity at 0.1 C-rate. equal to". As is known to those skilled in the art, “C-rate”(s) of 0.1, 1, 10, 100, etc. are well-known technical terms among those that act on the characterization of batteries. As used herein, "1 C-rate" means that a constant discharge current will discharge the entire battery in one hour, or a constant charge current will charge the battery in one hour. As used herein, "0.1 C-rate" means that the current is 10 times less and will charge/discharge the battery in 10 hours. In practice, first calculate the “theoretical capacity” of A*h (or mA*h) of the battery based on the amount of active material in the battery and the specific capacity of the material. Then, by dividing this by the desired number of hours (1 hour for 1 C, 5 hours for 0.2 C, 10 hours for 0.1 C, 0.1 hours for 10 C, etc.), the charge/discharge current is calculated. This current is then used to measure the battery charge or discharge capacity, which is referred to as the charge or discharge capacity at its C-rate.

In some aspects, the battery is a single cell configuration. 1A shows a schematic diagram of a battery 100 according to the invention in a single cell configuration. In some such aspects, 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 , which is adjacent to the second packaging layer 101 . adjacent to The anode layer 102 and/or the cathode layer 104 may be configured to include attachment points for the battery tab 106 .

In some aspects, the battery is a multi-cell configuration. 1B shows a schematic diagram of a battery 110 according to the present invention in a multi-cell configuration. In some such aspects, multiple alternating anode layers 102 and cathode layers 104 are arranged between separator layers 103 and packaging layers 101 . Each anode layer 102 and/or cathode layer 104 may be configured to include an attachment point for a battery tab. For the anode layer 102 , the battery tab is suitably a copper tab or lead 105 . For the cathode layer 104 , the battery tab is suitably an aluminum tab or lead 106 . In the multi-cell configuration, some electrodes in the inner portions of the multi-cell are in contact with the separator film 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 the multi-cell configuration battery 110 has additional anodes, cathodes in addition to those shown in FIG. 1B , as indicated by an optional additional layer 111 . , and/or separator layers. Battery 110 may be similar to battery 100 in some aspects.

The electrode according to the invention can be prepared according to any suitable means known to the person skilled in the art. For example, an anode and/or cathode may be fabricated using the methods and apparatus disclosed in U.S. Patent Application Serial No. 15/665,171, filed July 31, 2017, entitled "Standalone Electrodes and Methods of Making the Same." can The method for manufacturing a self-supporting electrode having an embedded tab is entitled “Method For Embedding A Battery Tab Attachment without a current collector or binder” (Method For Embedding A Battery Tab Attachment) In A Self-Standing Electrode Without Current Collector Or Binder, U.S. Patent Application Serial No. 16/123,872. The method of making the tab configuration shown herein, among other configurations, is entitled "Production of Carbon Nanotube Supported Freestanding Electrodes for Flexible Li-ion Batteries", filed Sep. 6, 2018. (Production Of Solely Carbon Nanotubes Supported Self-Standing Electrodes For Flexible Li-Ion Batteries) is disclosed in US Patent Application No. 16/123,935. The disclosure of each of the foregoing applications is expressly incorporated herein by reference. Carbon nanotubes suitable for use in the method of the present invention include single-walled nanotubes, few-walled nanotubes, and multi-walled nanotubes. In some aspects, the carbon nanotubes are single-walled nanotubes. Few-walled nanotubes and multi-walled nanotubes are synthesized, characterized, co-deposited, and collected using any suitable methods and apparatus known to those of skill in the art, including those used for single-walled nanotubes. can be

Suitable separator materials include, but are not limited to, a membrane barrier or separator membrane between the battery anode and cathode to provide a barrier between the anode and cathode while allowing the exchange of metal ions from one side to the other. Included are those known to those skilled in the art for use. 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 metal ions to migrate from the cathode side to the anode side and back again during the charge-discharge cycle. However, the separator film is impermeable to the anode material and cathode material, preventing them from mixing, touching and shorting the battery. The separator film also serves as an electrical insulator for the metal parts of the battery (leads, tabs, current collectors, metal parts of the enclosure, etc.), preventing the metal parts from touching and shorting. The separator membrane also prevents the flow of electrolyte.

In some aspects, the separator is a thin (15-25 μm) polymer membrane (three-layer composite: polypropylene-polyethylene-polypropylene; available for purchase). The thin polymer film can be between 15 and 25 μm thick. The two relatively thick porous electrode sheets may each independently be 50 to 500 μm thick.

Polymers used in polymer pouch cells are suitable for use in electrochemical cells, for example to protect the electrochemical cells from the external environment or, in the case of flexible batteries used in wearable devices, also to protect users from electrochemical cells. It may be any suitable polymer. As is known to those skilled in the art, a pouch cell refers to an outer packaging material having electrodes and separator(s) therein, and an electrolyte. Suitable materials include those known to those skilled in the art, for example polyethylene (including polyethylene- or polypropylene-coated aluminum, for example polyamide (JIS Z1714): 0.025 mm (±0.0025 mm), adhesives (polyester -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)), PTFE, PDMS, etc. Batteries according to the present invention may be assembled using any suitable method, including those known to those skilled in the art.

Battery tabs may be attached to the electrodes, in accordance with an aspect of the present invention, to a protrusion that extends from the body of each electrode past the separator film and does not overlap the other electrode, or a cutout in the opposite electrode and separator film. may be attached to the body of each electrode. Suitable battery tab materials and methods of attachment include those known to those skilled in the art. It should be understood that the battery tab disclosed herein is not a current collector.

In some aspects, batteries according to the present invention are assembled by disposing a separator between a fully fabricated anode and a fully fabricated cathode without any further repressing. As used herein, a "fully fabricated" anode or cathode is one that has been pressed and attached to a tab. In some aspects, batteries according to aspects of the present invention are assembled by placing a separator between a pre-pressed anode and a pre-pressed cathode and pressing them together. As used herein, a “pre-pressed” electrode is one that has been pressed but may or may not be attached to the tab, or may or may not be embedded within the tab attachment. In some aspects, a battery can be assembled by placing a separator between one unpressed first electrode (anode or cathode) and a pre-pressed electrode (anode or cathode), and the entire assembly can be pressed together.

Preferably, the concentration of carbon nanotubes on the surface of the electrode facing the separator is higher (from 5 to 100% by weight of nanotubes) than in the bulk of the electrode (from 0.5 to 10% by weight of nanotubes), but not facing the separator The concentration of carbon nanotubes on the surface of the non-electrode is lower (0 to 1% by weight of nanotubes) than in the bulk of the electrode (Figure 3). Composite materials comprising more than about 5% nanotubes are considered by those skilled in the art to be very sticky and will stick to separator membranes and stainless steel (which is a typical material from which the rollers of roller mills are made), as well as many other materials. will be. For example, a composite material containing (especially when freshly prepared) 5% nanotubes, 95% NMC (Lithium Nickel Manganese Cobalt Oxide, LiNi _x Mn _y Co _z O ₂ ) adheres well to rollers, preventing the composite from tearing. Without it, it is difficult to separate it from the roller. However, the same material "dusted" with NMC powder will not stick to the roller in any appreciable amount. This “border layer” can be 2 to 5 times thicker than the average size of the active material particles/flakes; For example, for NMC particles used in cathodes, with an average diameter of about 10 μm, a “boundary layer” of 20-30 μm thickness with increased or decreased nanotube content may be sufficient. According to an aspect of the present invention, this distribution of carbon nanotubes on or within the electrode promotes adhesion of the electrode to the separator film, while promoting adhesion to the rollers and other elements of the pressing apparatus (for the pressed electrode and the pressed battery). will reduce adhesion. This distribution can be achieved by varying the ratio(s) of the nanotube aerosol to the active material aerosol(s) during growth of the electrode material (i.e., the ratio of the weight of nanotubes deposited per unit time to the weight of active material deposited per equal unit time). can be achieved (eg 100% active material aerosol at the beginning of the synthesis, 97% active material aerosol and 3% nanotube aerosol during most of the synthesis, and 100% nanotube aerosol at the end of the synthesis). For example, in accordance with the present invention, a nanotube synthesis reactor can be configured to produce about 2 mg per hour of aerosolized nanotubes (amount deposited on the frit/filter). In the same setup, the NMC feeder can be set to aerosolize about 2 to 600 mg of NMC particles per hour (also deposited on the same filter). Thus, depending on the setup for the NMC feeder, materials containing from 50% nanotubes (2 mg + 2 mg) to about 0.3% nanotubes (2 mg + 600 mg) can be deposited. Running only the nanotube reactor (NMC feeder off) produces 100% nanotube material, while running only the NMC feeder (nanotube reactor off) produces 0% nanotube material (NMC powder). A suitable method of varying the ratio of nanotube aerosol to active nanotube aerosol(s) during growth is disclosed in U.S. Patent Application Serial No. 15/665,171, filed July 31, 2017, entitled "Freestanding Electrodes and Methods of Making Same." including, but not limited to, those disclosed in

Batteries can have any size, ie, any length, width, and height. In some aspects, the thickness of the battery is between 0.01 mm and 10 mm. In some aspects, the length and width are each independently 0.1 mm to 10000 mm.

2a and 2b show a battery according to the invention. A complete pouch battery cell contains 3x4 cm electrodes. The battery thickness is 3 mm. In the flat configuration ( FIG. 2A ), the battery 200 operates to power electronic appliances and electronic devices. Even after bending multiple times in various angles and in various directions, the battery 200 was still able to power the electronic device. In a wound configuration ( FIG. 2B ), battery 200 may be similar to battery 100 in some aspects.

For battery 300 in the configuration as shown in FIG. 3A , all electrodes (eg, anode 102 and cathode 104 in FIG. 3A ), as well as the battery in the multi-cell configuration shown in FIG. 3B . When the inner electrodes 102, 104 of 310 are in contact with the separator film 103 on both sides, on both surfaces of the electrode (ie, on both sides of the anode 102 in contact with the separator film 103 on both sides) , and it is advantageous to have an increased nanotube content 402 (in the electrode) (in the electrode) on both sides of the cathode 104 both in contact with the separator film 103 ( FIG. 4a ). In FIG. 4A , the center of the electrode comprises a bulk electrode material 401 comprising from 0.5 to 10% by weight of nanotubes. Moving outward from the electrode center towards the separator film 103, the band 402 comprises an electrode material having an increased nanotube content, such as nanotubes, between 5 and 100% by weight. The band 402 is in contact with the separator film 103 on its outer edge, and the separator film 103 extends in the direction 405 from the side facing the band 402 to the side facing the roller or press as manufactured. Batteries 300 , 310 may be similar to battery 100 in some aspects.

The difference between FIGS. 3A-3B and 1A-1B is that an extra separator membrane layer 103 is added on both outer sides of the cell (both single cell configuration or multi-cell configuration), resulting in the mechanical integrity of the cell ( It improves integrity and allows for better sliding of the cells with respect to packaging. This extra layer of separator film 103 can even be wrapped around the assembled cell. All electrodes of the battery shown in FIGS. 3A and 3B (either single cell configuration or multiple cell configuration) will be in the configuration shown in FIG. 4A while the external electrodes of the battery shown in FIGS. 1A and 1B are in FIG. 4B . It will be the configuration shown in . In FIG. 4b , the outer side of the separator membrane 103 faces in the direction 405 towards the roller or press, and the inner side is a band of an electrode having an increased nanotube content, for example, 5 to 100% by weight of nanotubes. Head to (402). Continuing inward across band 402, the opposite side of band 402 faces a region of bulk electrode material 401 containing between 0.5 and 10% by weight of nanotubes. The opposite side of the region of bulk electrode material 401 then faces region 404 of reduced nanotube content comprising 0 to 1 wt % 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.

A cell assembly according to the present invention (i.e., an anode, a separator, and a cathode in a single cell configuration; or alternating layers of a separator layer, one or more anodes, one or more separators, and one or more cathodes in a multi-cell configuration) is provided in a pouch cell. It may be encapsulated flat (ie, as shown in FIGS. 1A, 1B, and 2A) or folded one or more times before being encapsulated in a pouch cell (as shown in FIG. 5). In a pouch cell battery 500 , a battery comprising layers of a separator film 103 , an anode 102 , a separator film 103 , a cathode 1-4 , and a separator film 103 is a packaging layer 101 . It is folded one or more times before being encapsulated by a pouch cell made of Electrolyte 107 is also suitably included in the pouch cell during encapsulation. Anode layer 102 and cathode layer 104 may each be configured to include an attachment point for a battery tab. For the anode layer 102 , the battery tab is suitably a copper tab or lead 105 . For the cathode layer 104 , the battery tab is suitably an aluminum tab or lead 106 . Battery 500 may be similar to battery 100 in some aspects.

Encapsulation in a pouch cell, eg, in packaging layer 101, after being previously folded can increase battery capacity but also reduce the flexibility of the battery. In the folded configuration, an additional separator film may be needed to prevent the electrodes from touching each other (or to prevent any of their electrical leads from touching each other). In some such aspects, it may be advantageous to include one or two extra layers of separator membrane such that a multi-cell configuration as shown in FIGS. 3A and 3B partially alternates: separator 103 , anode 102 , A separator 103 , a cathode 104 , and a separator 103 . Such an assembly not only simplifies the folded configuration shown in Figure 5, but also makes the battery mechanically stronger, allowing the battery to withstand further bending, folding, winding, flexing, and/or wear and tear; The reason is that the added separator layer facilitates sliding the cell assembly into the pouch cell and, even more importantly, packaging/encapsulating during bending, folding, bending, etc. while minimizing movement of cell components relative to each other. This is because the battery assembly as a whole slides in relation to it. Such movement of internal cell components relative to each other can be detrimental to cell performance. This configuration for the electrode (cathode or anode or both) material preferably has an increased nanotube concentration on both sides, ie on both sides of the electrode in contact with the separator membrane. By having an increased concentration of nanotubes at the electrode side, the electrode will adhere well to both separator membranes, facilitating assembly and/or pressing of the entire five-layer cell assembly, since only the separator membrane(s) This is because only the rollers or other equipment will touch. If only one extra separator film is used, the electrode material side not in contact with or facing the separator film preferably has a reduced nanotube content on the side not in contact with the separator film.

In one embodiment, the flexible battery of the present invention provides not only a power source for a wearable sensor or device, but also a platform for integration of an electronic device, eg, a sensor. Specifically, the surface of the packaging layer 101 of the flexible battery is used as a substrate for attaching, printing and/or embedding electronic devices. 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, respiration rate, blood pressure, blood oxygen saturation, body temperature, muscle activity, seizure events, electroencephalogram (EEG), epileptic crisis, electroencephalogram (ECG), electromyography data (EMG), and skin electrical activity (EDA). those for detecting Additional examples of suitable sensors include those for monitoring the concentration of contaminants and movement of objects. In one embodiment, wearable devices integrated with flexible batteries have a wide range of applications including monitoring of environmental pollution, space exploration, homeland security, biology and medicine. One of the desirable applications of wearable sensors/devices is real-time monitoring of human physiological parameters.

6 illustrates 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, as shown, 3 and 4 may be attachments for the power supply device 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 . Elements 1 to 8 in Fig. 6 are for illustrative purposes only and are not intended to be limiting to a single preferred embodiment. For example, components 5 through 8 may individually be embedded within the electronic device 1 , or may be integrated together in any useful combination to form a sensor composite for a particular purpose. The microprocessor integration enables on-board processing of data collected by various types of sensors. Alternatively, the data collected by the sensors may be uploaded via an antenna to an app running on a separate mobile processing device, such as a smartphone. Mobile processing devices enable fast computation and simultaneous display of collected data. Further, depending on the structure of the sensor complex, both on-board processing and remote processing by the mobile device may be performed simultaneously.

Compared to some common commercial wearable devices such as watches, the wearable device of the present invention integrated with a flexible battery represents a clear advantage in real-time monitoring of human physiological state. A flexible battery as a substrate provides power directly to sensors and other electronic devices embedded within the packaging layer, and does not require a separate power source. A flexible battery as a substrate creates a very large contact area by additionally providing ample space for a large number of buried sensors and other electronics, whereas a watch has quite limited space to integrate everything and does not come close to a single point. Otherwise, the contact area of the sensor is also limited. More sensors with a larger contact area as shown by the wearable device of the present invention will read physiological parameters more accurately and faster. Flexible batteries can take many forms, such as straps, wristbands, and patches. Accordingly, the wearable device of the present invention integrated with the flexible battery may be attached to the limbs of a human or animal, such as a wrist/ankle band or strap, if necessary, and may be attached to the body or head as a strap or patch. In this way, the wearable device of the present invention can be placed at the most desirable location of a subject, such as an animal or human, to obtain a more accurate and faster reading of physiological parameters.

The dimensions of components 5 through 8 of FIG. 6 range from a few micrometers to a few millimeters. Due to the small footprint of embedded sensors and electronics, the wearable devices of the present invention integrated with flexible batteries are comfortable to wear, flexible, lightweight, compact, and washable.

This written description discloses, by way of example, the present invention, including preferred embodiments, and allows those skilled in the art to practice the invention, including making and using any device or system and making any included method. make it possible The patentable scope of the invention is defined by the claims, and may include other examples occurring to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that differ little from the literal language of the claims. Aspects from the various embodiments described and other known equivalents to each such aspect may be mixed and matched by those skilled in the art to construct further embodiments and techniques in accordance with the principles of this application.

Although aspects described herein have been described in conjunction with the exemplary aspects outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents will occur to those skilled in the art, whether known or presently unpredicted or unpredicted, to those skilled in the art. It can be obvious. Accordingly, the exemplary aspects as described above are intended to be exemplary and not limiting. Various changes may be made without departing from the spirit and scope of the present invention. Accordingly, this invention is intended to cover all known or hereinafter developed alternatives, modifications, variations, improvements, and/or substantial equivalents.

According to some aspects, a flexible battery having a packaging layer; Disclosed herein is a flexible battery assembly comprising an electronic device embedded within, attached to, and/or printed on a packaging layer such that the flexible battery provides power to the electronic device. The flexible battery assembly may be configured to be wearable by a user. In a non-limiting example, the flexible battery may be configured to be operable to attach to a limb, torso, or head of an animal or human. The flexible battery assembly may be in the form of a wristband, ankleband, headband, strap, headphone, shoe, patch, prosthesis, clothing, hat, hearing aid, and combinations thereof. For example, an electronic device may include sensors, processors, wireless communication/transmission devices, circuit boards, power generation devices (eg, solar cells, nanogenerators, thermoelectric generators, electrical generators), electronic equipment , GPS, displays, and combinations thereof. In some embodiments, the electronic device may be detachable from the packaging layer of the flexible battery. For example, the sensors may include a heart rate sensor, a respiratory rate sensor, a blood pressure sensor, a blood oxygen sensor, a body temperature sensor, a muscle activity sensor, a seizure event sensor, an electroencephalogram (EEG) sensor, an epilepsy crisis sensor, an electroencephalogram (ECG) sensor, electromyography data ( an EMG) sensor, an electrodermal activity (EDA) sensor, a contaminant sensor, a motion sensor, and combinations thereof, wherein the sensors are operative to provide data, the data being transmitted from the electronic device. In some embodiments, the sensors further comprise an emergency transmitter in communication with one or more of the sensors, wherein the emergency transmitter includes one or more of the sensors for a threshold measurement, eg, a seizure event threshold, a hypothermia threshold, or a low heart rate threshold. When it arrives, it is activated to transmit a signal.

In some embodiments, a flexible battery as an integrated platform for an electronic device provides an integrated platform for other batteries.

Accordingly, the claims are not intended to be limited to the aspects set forth herein, but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular unless specifically stated otherwise. It is not intended to mean "only one," but rather, "one or more." All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known to those skilled in the art or come later are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claimed element should be construed as means+function, unless the element is explicitly referred to by the use of the phrase "means for".

Also, the word “example” is used herein to mean “serving as an example, instance, or illustration.” Any aspect described herein as an "example" is not necessarily to be construed as preferred or advantageous over other aspects. Unless specifically stated otherwise, the term “some” 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” refer to A, B, and/or C may include any combination of and may include a plurality of As, a plurality of Bs, or a plurality of Cs. Specifically, 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 A alone, B alone , C alone, A and B, A and C, B and C, or A and B and C, wherein any such combination may include one or more members or members of A, B, or C. Nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.

The examples are offered to provide those skilled in the art with a complete disclosure and description of how to make and use the present invention, and are not intended to limit the scope of what the inventors consider their invention to be of any or all of the following experiments. It is not intended to represent that this is an experiment. Efforts have been made to ensure accuracy with respect to numbers used (eg, amounts, dimensions, etc.), but some experimental errors and deviations should be accounted for.

Moreover, all references throughout this application, eg, patent documents, including issued or registered patents or equivalents; Patent Application Gazette; and non-patent literature documents or other source material, as if individually incorporated by reference, are incorporated herein by reference in their entirety.

It will be appreciated that various implementations of the foregoing and other features and functions, or alternatives or variations thereof, may be combined, preferably in many other different systems or applications. In addition, various alternatives, modifications, variations or improvements not currently foreseen or anticipated may subsequently occur by those skilled in the art, which are also intended to be encompassed by the following claims.

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Claims (16)

A flexible battery assembly comprising:
a flexible battery with a packaging layer;
An electronic device, wherein the flexible battery is embedded in, attached to, and/or printed on the packaging layer to provide power to the electronic device.
including,
wherein the flexible battery is folded within the packaging layer. The flexible battery assembly of claim 1 , wherein the flexible battery assembly is configured to be wearable by a user. The flexible battery assembly of claim 1 , wherein the electronic device comprises sensors, processors, wireless communication/transmission devices, circuit boards, electronics, GPS, displays, and combinations thereof. 4. The epileptic crisis of claim 3, wherein the sensors are a heart rate sensor, a respiratory rate sensor, a blood pressure sensor, a blood oxygen sensor, a body temperature sensor, a muscle activity sensor, a seizure event sensor, an EEG sensor, an epileptic crisis. Flexible batteries, including (epileptic crisis) sensors, electroencephalogram (ECG) sensors, electromyography data (EMG) sensors, electrodermal activity (EDA) sensors, contaminant sensors, movement sensors, and combinations thereof assembly. The flexible battery assembly of claim 2 , wherein the flexible battery is in the form of a wristband, ankleband, headband, strap, headphone, shoe, patch, clothing, hat, hearing aid, and combinations thereof. The flexible battery assembly of claim 2 , wherein the flexible battery is shaped to be operable to attach to a limb, torso, or head of an animal or human. The flexible battery assembly of claim 3 , wherein the sensors are operative to provide data, the data being transmitted from the electronic device. 5. The flexible battery assembly of claim 4, further comprising an emergency transmitter in communication with one or more of the sensors, the emergency transmitter operative to transmit a signal when one or more of the sensors reaches a threshold measurement. The flexible battery assembly of claim 1 , wherein the electronic device comprises an electric power generation device. The flexible battery assembly of claim 9 , wherein the power generating device is a solar cell, a nanogenerator, a thermoelectric generator, an electrical generator, or a combination thereof. The flexible battery assembly of claim 1 , wherein the electronic device is detachable from the packaging layer of the flexible battery. According to claim 1, wherein the packaging layer is a pouch cell (pouch cell), the pouch cell,
an anode comprising an anode composite material having particles of anode active material within a three-dimensional cross-linked network of carbon nanotubes;
a cathode comprising a cathode composite material having particles of cathode active material within a three-dimensional cross-linked network of carbon nanotubes; and
a flexible separator membrane between the anode and the cathode
A flexible battery assembly comprising a. delete A method of manufacturing a wearable integration platform for an electronic device, comprising:
providing a flexible battery having a packaging layer, wherein the flexible battery is folded within the packaging layer;
embedding one or more electronic devices within, printing on, and/or attaching one or more electronic devices to the packaging layer; and
electrically connecting the one or more electronic devices to the flexible battery;
A method comprising A method of manufacturing an electronic device, comprising:
assembling the electronic device by a method comprising printing on the flexible battery packaging, embedding within the flexible battery packaging, attaching to the flexible battery packaging, or a combination thereof; and
providing power to the electronic device from a flexible battery comprising the flexible battery packaging to form an electronic device, wherein the flexible battery is folded within the flexible battery packaging;
A method comprising The method of claim 15 , wherein the electronic device, the flexible battery packaging, and the flexible battery are wearable by a user.

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