Table of Contents

1 Printed Batteries: An Overview 1
Juliana Oliveira, Carlos Miguel Costa and Senentxu Lanceros-Méndez

1.1 Introduction 1

1.2 Types of Printed Batteries 7

1.3 Design of Printed Batteries 9

1.4 Main Advantages and Disadvantages of Printed Batteries 11

1.4.1 Advantages 11

1.4.2 Disadvantages 12

1.5 Application Areas 13

1.6 Commercial Printed Batteries 14

1.7 Summary and Outlook 14

Acknowledgements 15

References 16

2 Printing Techniques for Batteries 21
Andreas Willert, Anh-Tuan Tran-Le, Kalyan Yoti Mitra, Maurice Clair, Carlos Miguel Costa, Senentxu Lanceros-Méndez and Reinhard Baumann

2.1 Introduction/Abstract 21

2.2 Materials and Substrates 22

2.3 Printing Techniques 23

2.3.1 Screen Printing 25

2.3.1.1 Flatbed 25

2.3.1.2 Rotary 27

2.3.1.3 Screen Mesh 28

2.3.1.4 Squeegee 29

2.3.2 Stencil Printing 30

2.3.3 Flexographic Printing 31

2.3.3.1 Letterpress Printing 31

2.3.3.2 Flexography 32

2.3.4 Gravure Printing 33

2.3.5 Lithographic/Offset Printing 35

2.3.6 Coating 36

2.3.7 Inkjet 38

2.3.7.1 Inkjet Printing Technology and Applications 38

2.3.7.2 Selective View of the Market for Inkjet Technology 44

2.3.7.3 Advanced Applications: Printed Functionalities and Electronics 48

2.3.8 Drying Process 50

2.3.9 Process Chain 52

2.3.10 Printing of Layers 53

2.4 Conclusions 54

Acknowledgements 54

References 55

3 The Influence of Slurry Rheology on Lithium-ion Electrode Processing 63
Ta]Jo Liu, Carlos Tiu, Li-Chun Chen and Darjen Liu

3.1 Introduction 63

3.2 Slurry Formulation 64

3.3 Rheological Characteristics of Electrode Slurry 65

3.3.1 Viscosity and Shear-Thinning 65

3.3.2 Viscoelasticity 66

3.3.3 Yield Stress 68

3.4 Effects of Rheology on Electrode Processing 69

3.4.1 Composition of Electrode Slurry 69

3.4.2 Electrode Slurry Preparation 70

3.4.2.1 Mixing Methods 70

3.4.2.2 Mixing Devices 73

3.4.3 Electrode Coating 75

3.4.4 Electrode Drying 75

3.5 Conclusion 76

List of Symbols and Abbreviations 76

References 76

4 Polymer Electrolytes for Printed Batteries 80
Ela Strauss, Svetlana Menkin and Diana Golodnitsky

4.1 Electrolytes for Conventional Batteries 80

4.1.1 Polymer/Gel Electrolytes for Aqueous Batteries 81

4.1.2 Electrolytes for Lithium-ion Batteries 82

4.2 Electrolytes for Printed Batteries 84

4.2.1 Screen-printed Electrolytes 85

4.2.2 Spray-printed Electrolytes 86

4.2.3 Direct-write Printed Electrolytes 88

4.2.4 Laser-printed Electrolytes 99

4.3 Summary 107

References 108

5 Design of Printed Batteries: From Chemistry to Aesthetics 112
Keun-Ho Choi and Sang-Young Lee

5.1 Introduction 112

5.2 Design of Printed Battery Components 114

5.2.1 Printed Electrodes 114

5.2.2 Printed Separator Membranes and Solid-state Electrolytes 121

5.3 Aesthetic Versatility of Printed Battery Systems 126

5.3.1 Zn/MnO2 Batteries 126

5.3.2 Supercapacitors 132

5.3.3 Li-ion Batteries 134

5.3.4 Other Systems 138

5.4 Summary and Prospects 138

Acknowledgements 141

References 141

6 Applications of Printed Batteries 144
Abhinav M. Gaikwad, Aminy E. Ostfeld and Ana Claudia Arias

6.1 Printed Microbatteries 146

6.2 Printed Primary Batteries 151

6.3 Printed Rechargeable Batteries 160

6.4 High-Performance Printed Structured Batteries 169

6.5 Power Electronics and Energy Harvesting 174

References 182

7 Industrial Perspective on Printed Batteries 185
Patrick Rassek, Michael Wendler and Martin Krebs

7.1 Introduction 185

7.2 Printing Technologies for Functional Printing 186

7.2.1 Flexography 188

7.2.2 Gravure Printing 190

7.2.3 Offset Printing 192

7.2.4 Screen Printing 193

7.2.5 Conclusion 197

7.3 Comparison of Conventional Battery Manufacturing Methods with Screen Printing Technology 197

7.4 Industrial Aspects of Screen-printed Thin Film Batteries 200

7.4.1 Layout Considerations 200

7.4.1.1 Sandwich Architecture (Stack Configuration) 200

7.4.1.2 Parallel Architecture (Coplanar Configuration) 201

7.4.2 Carrier Substrates and Multifunctional Substrates for Printed Batteries 203

7.4.2.1 Barrier Requirements and Material Selection 205

7.4.2.2 Process Requirements of Qualified Materials 206

7.4.3 Current Collectors 209

7.4.4 Electrodes 210

7.4.5 Electrolytes and Separator 214

7.4.6 Encapsulation Technologies 215

7.4.6.1 Screen Printing of Adhesives 215

7.4.6.2 Contact Heat Sealing 216

7.4.6.3 Ultrasonic Welding 217

7.4.7 Conclusion 219

7.5 Industrial Applications and Combination With Other Flexible Electronic Devices 220

7.5.1 Self-powered Temperature Loggers 220

7.5.2 Smart Packaging Devices 222

7.6 Industrial Perspective on Printed Batteries 223

7.6.1 Competition with Conventional Batteries 223

7.6.2 Cold Chain Monitoring 225

7.6.3 Health]monitoring Devices 226

7.7 Conclusion 226

References 227

8 Open Questions, Challenges and Outlook 230
Carlos Miguel Costa, Juliana Oliveira and Senentxu Lanceros-Méndez

Acknowledgements 233

References 233

Index 235

About the Author

SENENTXU LANCEROS-MÉNDEZ, PHD, is Ikerbasque Professor at BCMaterials, Basque Center for Materials, Applications and Nanostructures, Spain and Associate Professor at the Physics Department of the University of Minho, Portugal. His work is focused in the area of smart and multifunctional materials for sensors and actuators, energy, and biomedical applications.

CARLOS MIGUEL COSTA, PHD, is Researcher at the Physics and Chemistry Centers of the University of Minho, Portugal. His work is focused in the development of advanced polymer composites and novel materials and formulations for energy storage applications, including lithium-ion batteries, sodium-ion batteries, and printed batteries.