A reliable sealing method for microbatteries

As electronic devices continue to become smaller, their energy sources (i.e., batteries) also need to be smaller. Typically, energy densities of batteries decrease as the battery size decreases due to the relative increase of parasitic weight such as packaging materials. In addition, the sealing methods in conventional batteries are difficult to apply to microbatteries. In this work, we developed a facile sealing method for microbatteries. The method employs a dual-sealing concept: a first rubber barrier temporally confines the organic electrolytes and a second adhesive barrier forms a hermetic seal with the battery case. With this innovative sealing approach, excellent shelf life and operation life of the batteries have been demonstrated. A minimal amount of packing materials is employed resulting in high energy densities. •A facile method for sealing mini-size or irregularly shaped batteries was developed.•The first sealing barrier blocks liquid electrolytes.•The second sealing barrier hermetically seals the cell.•The sealing method is low-cost and widely applicable.