Ultrathin Flexible Batteries Power Disposable Electronics Revolution

Truly successful technologies - those that achieve widespread commercial application - generally exhibit a number of characteristics. Chiefest among them is probably the ability to help humans do a lot of things that they would be doing anyway, but do them faster, cheaper, and more easily.

Automobiles, for example, did not make people peripatetic. People have been wandering around Earth's surface for hundreds of thousands (maybe millions) of years. They've been doing it since long before the modern species homo sapiens developed. All the automobile did was up the cruising speed from around 2 mph to several tens of mph. Human behavior didn't change, they still like to go from A to B whenever they can come up with an excuse, the automobile achieved enormous commercial success by making it possible to do it faster, cheaper, and more easily. What pushed the automobile's success to the enormous dimensions it achieved was the fact that its advantages applied to almost everything people do, from enjoying an afternoon tryst to seeking out new worlds to conquer.

Ultrathin, flexible, disposable battery technology should have similar success. It seems like such a simple thing: use thick-film technology to manufacture carbon-zinc batteries on a flexible substrate. How hard can it be to manufacture a battery consisting of a handful of non-moving parts compared to the typical automobile's 3.7 kazillion moving parts? You make the things with a glorified ink-jet printer. What could be easier?

Well, it isn't all that easy to make the things thin enough, reliable enough, and consistent enough for commercial success. It's simple to imagine doing it. The Devil's in the details of doing it right. Only a few companies have managed it.

Blue Spark Technologies is one of them. In an article published in yesterday's Designfax online newsletter, Matt Ream, Blue Spark's marketing manager and an electronics engineer with 20 years of experience in high-tech electronics and radio frequency identification (RFID) technology, reviews ultrathin battery technology and presents a cross section of applications.

He says that products using the company's technology rely on convergence of printed electronics and thin, flexible printed battery technologies. Printed electronics is the printing of electronic devices on common media, such as paper, plastic, or textiles, using traditional printing processes. Examples include programmable chips (ICs), RFID antennas and tags, printed displays, and thin, flexible batteries that provide a low-voltage power source. Ream goes on to report that industry analyst IDTechEx predicts that the market potential for printed electronics will grow to over $35 billion by 2018, while NanoMarkets predicts sales of thin film and printed batteries will grow to over $5 billion by 2015.

For product designers of low-voltage electronic products and systems, Ream says his company's 1.5-V printed carbon-zinc batteries offer multiple advantages over traditional button and coin cells, such as:

• Eco-friendly, safe disposability, since they contain no lithium, mercury, or other toxic materials.

• Small form factor, thin profile, and customizable shapes with a thickness range from about 430 to 700 microns (0.017 to 0.027 in.), and peak drain currents of at least 1 mA.

• Lower production and integration costs because they are made using conventional printing processes, and can often be printed or mounted on the same substrate as other printed electronics.

Such batteries can be used in applications where integration of a conventional battery would be too complex and costly. Within limits, users can typically specify size and shape (linear and non-linear), overall voltage, storage capacity, and thickness -- all tailored to the application requirements.

In a CNBC interview, Gary Johnson, the company's CEO, and Michael Liard, RFID Practice Director for ABI Research, described the market potential for ultrathin disposable batteries. Basically, you can look forward to seeing the technology attached to, pasted on, or incorporated into all kinds of disposable items that you use every day. Actually, you won't know that you're seeing them. They'll sit there in the background making it possible to do faster, cheaper, and easier what you were going to do, anyway.