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Micropunching Lithography for Generating Micro- and Submicron-patterns on Polymer Substrates
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High-throughput production of microbatteries by a stack-punching method.

Zhaofeng Ouyang1, Yan Wang1, Yongyi Zhong2

  • 1Frontiers Science Center for Transformative Molecules, State Key Laboratory of Synergistic Chem-Bio Synthesis, School of Chemistry and Chemical Engineering, and Zhangjiang Institute for Advanced Study, Shanghai Jiao Tong University, Shanghai, China.

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A novel top-down stack-punching method enables high-throughput production of uniform microbatteries. This approach overcomes limitations of traditional methods, paving the way for advanced electronics and biohybrid systems.

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Area of Science:

  • Materials Science and Engineering
  • Energy Storage Technologies
  • Microfabrication

Background:

  • Microbatteries are essential for powering integrated circuits, wearable devices, and medical implants.
  • Current bottom-up assembly methods for microbatteries face challenges in production efficiency, uniformity, and electrochemical performance.
  • Limitations hinder the widespread practical application of microbattery technology.

Purpose of the Study:

  • To develop a high-throughput manufacturing approach for microbatteries.
  • To address the limitations of conventional microbattery fabrication techniques.
  • To create robust electrode-electrolyte interfaces for high-speed manufacturing processes.

Main Methods:

  • A top-down stack-punching approach was employed for microbattery fabrication.
  • An anode-free design was integrated with an interpenetrating positive electrode|electrolyte fusion layer.
  • This design ensures robust interfaces capable of withstanding mechanical stress during high-speed punching.

Main Results:

  • The stack-punching method achieved a high production rate of 1800 units per hour.
  • Microbatteries exhibited high uniformity in physical dimensions and electrochemical performance.
  • A maximum volumetric energy density of 1306 mWh cm-3 was achieved, competitive with current technologies.

Conclusions:

  • The top-down stack-punching approach offers a viable solution for large-scale microbattery manufacturing.
  • This method facilitates the production of high-performance, uniform microbatteries.
  • The developed microbatteries show potential for integration into microsensors and biohybrid systems.