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Open AccessArticle

A Minimal Volume Hermetic Packaging Design for High-Energy-Density Micro-Energy Systems

Department of Mechanical Engineering and Applied Mechanics, University of Pennsylvania, Philadelphia, PA 19104, USA
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This paper is an extended version of our paper published in Proceedings of PowerMEMS 2019, Kraków, Poland, 2–6 December 2019; pp. 1–4, doi:10.1109/PowerMEMS49317.2019.30773702286.
Energies 2020, 13(10), 2492; https://doi.org/10.3390/en13102492
Received: 27 April 2020 / Revised: 13 May 2020 / Accepted: 14 May 2020 / Published: 15 May 2020
Hermetic packaging is critical to the function of many microscale energy storage and harvesting devices. State-of-the-art hermetic packaging strategies for energy technologies, however, are designed for macroscale devices and dramatically decrease the fraction of active materials when applied to micro-energy systems. We demonstrated a minimal volume hermetic packaging strategy for micro-energy systems that increased the volume of active energy storage materials by 2× and 5× compared to the best lab scale microbatteries and commercial pouch cells. The minimal volume design used metal current collectors as a multifunctional hermetic shell and laser-machined hot melt tape to provide a thin, robust hermetic seal between the current collectors with a stronger adhesion to metals than most commercial adhesives. We developed the packaging using commercially available equipment and materials, and demonstrated a strategy that could be applied to many kinds of micro-energy systems with custom shape configurations. This minimal, versatile packaging has the potential to improve the energy density of current micro-energy systems for applications ranging from biomedical devices to micro-robots. View Full-Text
Keywords: hermetic packaging; IoT; MEMS; microbattery; battery; harvester hermetic packaging; IoT; MEMS; microbattery; battery; harvester
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MDPI and ACS Style

Yue, X.; Grzyb, J.; Padmanabha, A.; Pikul, J.H. A Minimal Volume Hermetic Packaging Design for High-Energy-Density Micro-Energy Systems. Energies 2020, 13, 2492.

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