Microfabrication of Miniature Batteries for Advanced Wireless Sensors

The increased reliance on small sensors and other electronic components in vehicles and elsewhere has accelerated demand for energy storage that is easily developed, flexibly deployed and inexpensive. Needs range from microscopic power sources for autonomous sensor networks, to larger conformal and irregular-shaped batteries. The purpose of this work is to respond to this need by demonstrating simple but powerful processes for making lithium-ion (Li-ion) batteries. Methodologies for making both microscopic and larger batteries of almost any size and shape are proposed. Two fabrication processes that can be used to answer this need. The first is a dry (solvent-free) manufacturing approach to make battery electrodes and separators. The second is roll-to-roll, previously demonstrated for making both thermal batteries and lithium ion (Li-ion) cells and batteries. These will be used to make conformal and irregularly shaped batteries, of variable capacity and irregular shapes and sizes. Phase I will be focused on proof-of-concept demonstration of conformal and irregular shaped batteries, including high temperature batteries. Phase II will involve more mature engineering of the manufacturing technologies to make batteries according to specifications provided by DOE. US competitiveness in battery manufacturing will improve using this improved manufacturing approach. Sensors that include their own power source will represent a strong entry into the sensor industry. Vehicles that have irregularly shaped batteries will increase volume efficiency and vehicle functioning. The electronics industry will also benefit from sensors with improved efficiency, functioning and ease of application.