Flexible thin-film printed batteries with 3d printed substrates

Abstract

A method for printing a flexible printed battery is disclosed. For example, the method includes printing, via a three-dimensional (3D) printer, a first substrate of the flexible thin-film printed battery, printing a first current collector on the first substrate, printing a first layer on the first current collector, printing, via the 3D printer, a second substrate, printing a second current collector on the second substrate, printing a second layer on the second current collector, and coupling the first substrate and the second substrate around a paper separator membrane moistened with an electrolyte that is in contact with the first layer and the second layer.

What is claimed is: 
     
         1 . A flexible printed battery, comprising:
 a first substrate that is three dimensionally (3D) printed;   a first current collector on the first substrate;   a first layer on the first current collector;   a second substrate that is 3D printed;   a second current collector on the second substrate;   a second layer on the second current collector; and   a paper separator membrane moistened with an electrolyte, wherein the first substrate and the second substrate are coupled around the paper separator membrane such that the paper separator membrane is in contact with the first layer and the second layer.   
     
     
         2 . The flexible printed battery of  claim 1 , wherein first substrate is 3D printed onto a surface of an object that is 3D printed. 
     
     
         3 . The flexible printed battery of  claim 2 , wherein a shape of the first substrate is identical to a shape of the surface of the object. 
     
     
         4 . The flexible printed battery of  claim 2 , wherein the first substrate is printed as an integral part of the object. 
     
     
         5 . The flexible printed battery of  claim 2 , wherein the shape of the surface is curved. 
     
     
         6 . The flexible printed battery of  claim 5 , wherein the shape of the surface is convex. 
     
     
         7 . The flexible printed battery of  claim 1 , wherein the first substrate, the first current collector, and the first layer comprise a cathode, and the second substrate, the second current collector, and the second layer comprise an anode. 
     
     
         8 . The flexible printed battery of  claim 1 , wherein the first substrate, the first current collector, and the first layer comprise an anode, and the second substrate, the second current collector, and the second layer comprise a cathode. 
     
     
         9 . The flexible printed battery of  claim 1 , wherein the paper separator membrane is encapsulated via a thermal bonding process. 
     
     
         10 . The flexible printed battery of  claim 9 , wherein edges of the first layer and edges of the second layer are sealed to encapsulate the paper separator membrane between the first layer and the second layer. 
     
     
         11 . The flexible printed battery of  claim 1 , further comprising:
 a copper tape attached to an end of the first current collector and to an end of the second current collector.   
     
     
         12 . A flexible printed battery, comprising:
 a first thermoplastic substrate that is three dimensionally (3D) printed;   a first current collector on the first thermoplastic substrate;   a first layer on the first current collector;   a second thermoplastic substrate that is 3D printed;   a second current collector on the second thermoplastic substrate;   a second layer on the second current collector; and   a paper separator membrane moistened with an electrolyte, wherein the first thermoplastic substrate and the second thermoplastic substrate are coupled around the paper separator membrane such that the paper separator membrane is in contact with the first layer and the second layer.   
     
     
         13 . The flexible printed battery of  claim 12 , wherein the first thermoplastic substrate and the second thermoplastic substrate comprise at least one selected from a group of: a thermoplastic polyurethane, a thermoplastic elastomer, a polyester copolyamide thermoplastic elastomer, or a soft polyactic acid. 
     
     
         14 . The flexible printed battery of  claim 12 , wherein the first thermoplastic substrate is 3D printed onto a surface of an object that is 3D printed. 
     
     
         15 . The flexible printed battery of  claim 14 , wherein the first thermoplastic substrate and the object are printed from a same 3D printable material. 
     
     
         16 . The flexible printed battery of  claim 14 , wherein a shape of the first substrate is identical to a shape of the surface of the object. 
     
     
         17 . The flexible printed battery of  claim 14 , wherein the shape of the surface is curved. 
     
     
         18 . The flexible printed battery of  claim 17 , wherein the shape of the surface is convex. 
     
     
         19 . The flexible printed battery of  claim 12 , wherein edges of the first thermoplastic layer and edges of the second thermoplastic layer are thermally bonded form a seal and encapsulate the paper separator membrane between the first layer and the second layer. 
     
     
         20 . The flexible printed battery of  claim 12 , further comprising:
 a conductive material attached to a tab portion of the first current collector and to a tab portion of the second current collector.