Japanese company MICRONICS, which specializes in semiconductor measuring instruments, has partnered with GUALA TECHNOLOGY Co., Ltd., a materials application risk firm based in Kobe, to develop a mass production technology for a new type of "battenice" secondary battery (Fig. 1). The companies plan to start sample shipments in 2014.
This innovative battery offers several advantages over traditional lithium-ion batteries. First, it can be manufactured as a thin film using cost-effective methods, making it ideal for integration into wearable devices, flexible displays, and printed substrates. Its flexibility allows it to be shaped into various forms, expanding its potential applications.
Second, the battery features an all-solid construction that eliminates the risk of liquid leakage. It doesn’t use flammable materials, so it won’t catch fire, and it avoids rare metals and rare earths. It has already achieved over 10,000 charge-discharge cycles, promising long-term reliability.
MICRONICS aims to achieve an output voltage of 1.5V, energy density of 500Wh/L, power density of 8000W/L, and a cycle life of 100,000 times while operating within a temperature range of -25°C to +85°C.
(Fig. 1: Using the new principle, easy to implement flexibility)
Trial samples include a 100mm square battery (a), a stacked version with 8 thin films connected in parallel (b), and a 300mm square, 11μm thick prototype (c). At the “5th International Secondary Battery Exhibition†in February 2014, a trial product (d) was showcased alongside organic EL lighting fixtures, demonstrating the battery’s versatility and portability.
**Will not catch fire**
Although the unit volume energy density of the battenice battery is lower than that of conventional lithium-ion batteries like the 18650 cylindrical cell (650Wh/L), its unique properties are expected to open up new markets.
**Power storage in band gap**
The battery's design differs from traditional ones, as it doesn't rely on chemical reactions but uses quantum technology. It stores energy in n-type metal oxide semiconductor particles coated with an insulating layer. During charging, electrons move into new energy levels within the band gap of the semiconductor, and they are released during discharging.
Materials such as titanium dioxide (TiO2), tin oxide (SnO2), and zinc oxide (ZnO) are used. Ultraviolet light is applied during manufacturing to create these energy levels, enabling efficient charge and discharge.
MICRONICS has produced thin film prototypes, including 100mm and 300mm square samples with a thickness of about 10μm. A multi-layered version with 32 films has also been developed. At the exhibition, the company demonstrated the use of these batteries with Konica Minolta’s organic EL lighting fixtures, showing their practicality in real-world applications.
**Low-cost manufacturing process**
The battery can be manufactured using a roll-to-roll continuous process, significantly reducing costs. Unlike chemical batteries, there's no need for a lengthy aging period, further cutting production expenses.
Currently, stainless steel and aluminum foils are used as substrates, but the company is working on technologies to reduce baking temperatures, potentially allowing the use of resins in the future.
**Speculative manufacturing method based on patent application**
While the exact process isn’t disclosed, the patent (WO2012046325A1) filed by GUALA TECHNOLOGY suggests a specific method. It involves sputtering a negative electrode and TiO2 layer onto a substrate, followed by spin-coating a mixture containing fatty acid titanium and silicone oil. After drying and calcination, a TiO2 fine particle layer surrounded by silicon is formed.
Ultraviolet irradiation at 254 nm creates new energy levels in the TiO2 band gap. A p-type semiconductor and positive electrode are then deposited via sputtering. Metal electrodes like copper, nickel, or aluminum can also be used, and multiple deposition techniques are described in patents.
**Challenges in increasing energy density**
To boost energy density, the battery could have thinner substrates and thicker charging layers. However, current limitations make it difficult to increase the number of layers beyond two due to challenges in uniform UV irradiation and handling very thin films.
If these issues are resolved, the energy density could be further improved from the current estimated 500Wh/L. (Author: Hiroshi Tomioka, Nikkei Online Technology)
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