Abstract
Hermetic packaging is critical to the function of many microscale energy storage and harvesting devices. State-of-the-art hermetic packaging strategies for energy technologies, however, are designed for macroscale devices and dramatically decrease the fraction of active materials when applied to micro-energy systems. We demonstrated a minimal volume hermetic packaging strategy for micro-energy systems that increased the volume of active energy storage materials by 2× and 5× compared to the best lab scale microbatteries and commercial pouch cells. The minimal volume design used metal current collectors as a multifunctional hermetic shell and laser-machined hot melt tape to provide a thin, robust hermetic seal between the current collectors with a stronger adhesion to metals than most commercial adhesives. We developed the packaging using commercially available equipment and materials, and demonstrated a strategy that could be applied to many kinds of micro-energy systems with custom shape configurations. This minimal, versatile packaging has the potential to improve the energy density of current micro-energy systems for applications ranging from biomedical devices to micro-robots.
Highlights
Hermetic packaging technologies that prevent internal components from reacting with oxygen or moisture in the air are critical for numerous microscale technologies, including sensors, batteries, super-capacitors, energy harvesters and other energy systems [1,2,3]
For example, have a minimum hot sealing width of 3 mm, which accounts for 12% of the total cell area in a 10 × 10 cm2 macroscale battery, and allows 88% of the cell area to be available for energy storing materials
We developed a low volume fraction micro-packaging strategy designed to increase the volumetric and gravimetric energy density of micro-energy storage technologies
Summary
Hermetic packaging technologies that prevent internal components from reacting with oxygen or moisture in the air are critical for numerous microscale technologies, including sensors, batteries, super-capacitors, energy harvesters and other energy systems [1,2,3]. The microbattery market, for example, is predicted to grow nearly 5× between 2019 and 2025 as a result of new Internet of Things (IoT) and medical devices [4], but current hermetic packaging technologies limit microbattery energy densities to a fraction of macroscale batteries. For example, have a minimum hot sealing width of 3 mm, which accounts for 12% of the total cell area in a 10 × 10 cm macroscale battery, and allows 88% of the cell area to be available for energy storing materials. When the same pouch cell packaging is applied to a 1 × 1 cm microscale cell, the seal uses 84% of the cell area and leaves only 16% of the area for energy storing materials. If the energy storing materials had a combined energy density of 1000 Wh/L, the macroscale cell would have 880 Wh/L energy density, while the microscale cell would have only 160 Wh/L
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