Ehsan Faegh | CCL Industries Inc. - Imprint Energy: Why is ambient air manufacturing the ultimate cost-killer for printed IoT batteries compared to lithium-ion?
00:11:52 - 00:13:55
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Why is ambient air manufacturing the ultimate cost-killer for printed IoT batteries compared to lithium-ion?
While lithium-ion batteries dominate high-capacity consumer electronics, their implementation in thin-film IoT labels is constrained by complex manufacturing demands and strict safety regulations. This segment compares printed zinc-based batteries directly with lithium-ion, outlining the operational and commercial advantages of a safer, flexible chemistry. Crucially, zinc batteries can be manufactured under ambient atmospheric conditions, entirely bypassing the multi-million dollar dry rooms required to process moisture-sensitive lithium compounds.
This process integration allows manufacturers to print batteries directly alongside circuitry and labels on standard roll-to-roll production lines. This eliminated packaging overhead translates directly to a thinner profile, as zinc cells do not require the heavy, rigid protective casing mandatory for volatile lithium-ion systems.
Furthermore, the environmental profile of zinc batteries is significantly superior, boasting a 92% lower carbon footprint. When paired with high power capabilities that support cellular IoT protocols and a safer transport profile free from aviation restrictions, the commercial case for zinc-based smart labels becomes highly compelling.
In this short video, you can learn:
* Why ambient air manufacturing eliminates the need for expensive dry rooms in battery production.
* How eliminating rigid casing allows zinc batteries to achieve a thinner form factor than lithium-ion.
* The environmental and regulatory benefits of zinc chemistry, including a 92% lower carbon footprint and unrestricted shipping.
📋 **Clip Abstract** Compare the core structural, processing, and environmental differences between printed zinc batteries and traditional lithium-ion cells. Learn how ambient-air printing yields ultra-thin, highly integrated IoT labels without the high cost of dry room infrastructure.
#AmbientAirManufacturing, #ZincChemistry, #RollToRollPrinting, #FlexiblePowerSources, #PrintedElectronics, #SmartPackaging
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00:08:44 - 00:10:52
Can printed batteries really withstand ultra-low cold chain temperatures without losing pulse discharge capability?
Can printed batteries really withstand ultra-low cold chain temperatures without losing pulse discharge capability?
Zinc-based printed batteries present a viable solution for demanding smart packaging and medical cold-chain tracking. This clip breaks down the operational threshold of Imprint Energy’s Zco battery technology, demonstrating its performance in extreme thermal environments from minus 35C up to 60C. Maintaining reliable discharge capability under these conditions is historically difficult for conventional chemistries due to reduced electrolyte conductivity at sub-zero temperatures.
The speaker details a dual-step pulse testing protocol designed to simulate real-world IoT transmission states: a longer, lower-power "scan pulse" for signal discovery, followed by a high-power, short-duration "transmission pulse" for data delivery. The battery manages around 250 pulses at ultra-low temperatures, scaling up to nearly 2,000 pulses at higher temperatures.
From a commercial standpoint, this resilience enables active tracking in pharmaceutical cold chains, such as COVID-19 vaccine transport requiring stable minus 20C environments. Furthermore, a shelf life of two years with over 75% capacity retention ensures long-term viability for globally distributed inventory.
In this short video, you can learn:
* How printed zinc batteries sustain pulse discharge across a broad temperature range of -35C to 60C.
* The mechanics of scan versus transmission pulses during active IoT tracking cycles.
* Why long shelf-life capacity retention makes printed zinc cells commercially competitive for pharmaceutical logistics.
📋 **Clip Abstract** Discover how advanced zinc-based printed batteries perform under extreme thermal environments down to -35C. Learn how dual-step pulse protocols validate these power sources for active medical cold-chain transmissions.
#PrintedZincCells, #PulseDischarge, #LowTemperatureElectrolytes, #ColdChainTracking, #PrintedElectronics, #SmartPackaging
00:16:40 - 00:17:24
Can zinc-anode batteries actually be rechargeable, or does passivation destroy them?
Can zinc-anode batteries actually be rechargeable, or does passivation destroy them?
The fundamental electrochemical bottleneck of zinc-based batteries has always been their poor rechargeability, driven by zinc anode shape change, passivation, corrosion, and hydrogen gas evolution. During a full discharge-charge cycle, the zinc anode undergoes significant structural shifting, which rapidly degrades the battery cell. This clip explains the precise scientific compromise required to unlock cycle life in printed zinc systems.
To circumvent these degradation pathways, the battery is operated at a limited Depth of Discharge (DOD) of less than 25%. By restricting how deeply the zinc is stripped during discharge, the anode maintains its structural scaffolding. This prevents the severe morphology changes and dendrite formation that typically lead to internal short circuits.
Under this controlled DOD operating window and paired with slower charging rates, the chemistry successfully suppresses side reactions like hydrogen evolution. This allows the printed cells to consistently achieve over a hundred charge-discharge cycles, opening up reusable smart label applications.
In this short video, you can learn:
* The primary chemical degradation mechanisms of zinc anodes, including passivation and hydrogen gas evolution.
* How limiting the Depth of Discharge (DOD) to under 25% preserves the physical structure of the anode.
* The operational trade-off that enables over 100 cycles in a printed zinc battery system.
📋 **Clip Abstract** Explore the electrochemical strategies used to make printed zinc batteries cycle-stable. Learn how restricting the depth of discharge to less than 25% prevents anode structural degradation and hydrogen evolution.
#ZincAnodes, #DepthOfDischarge, #AnodePassivation, #DendriteSuppression, #PrintedElectronics, #SmartLabels