Electrospun Textile-Based Flexible Battery System for Wearable Energy Storage
This technology features electrospun sulfur-based cathode yarns in which sulfur powder or nanosulfur is embedded within conducting polymers (for example, polystyrene, polyaniline or PVdF) optionally reinforced with graphene and Group VI dopants. These cathode fibers are paired with either electrospun silicon-fiber anodes or porous lithium-metal foam anodes containing structural isomorphous alloys and thin lithium-ion-conducting coatings to inhibit dendrite growth. A flexible electrolyte separator of PVdF-HFP gel loaded with LiTFSI salt and nanoscale fillers (SiO₂, TiO₂, etc.) provides high ionic conductivity and mechanical compliance. All three components can be produced as standalone nonwoven mats or sequentially electrospun into layered films—anode current collector, active materials, electrolyte, cathode and polymer shell—and then woven or stitched into conformable, textile-like battery assemblies.
Description
What sets this approach apart is the integration of high-surface-area electrospun fibers and yarns that combine active material, conductive matrix and structural reinforcement in a single filament, enabling both high energy density and mechanical flexibility. The use of structural isomorphous alloys and lithium-ion-conducting coatings in the anode foam suppresses dendrites without sacrificing cyclability, while the gel-polymer electrolyte loaded with nanofillers boosts ionic transport and dimensional stability. Layer-by-layer electrospinning and textile weaving yield seamless, weavable energy storage architectures suitable for flexible electronics, wearables and custom-shaped devices.Applications
- Wearable smart textiles- Flexible medical sensor patches
- Conformable military battery packs
- Flexible power banks
- IoT device power supply
Advantages
- Flexible, conformable design suitable for wearable and textile-integrated electronics- High energy density enabled by sulfur-based cathodes and silicon or lithium-metal anodes
- Lightweight, ultra-thin construction for minimal bulk in portable devices
- Dendrite suppression and enhanced safety via structural isomorphous alloys and thin ion-conducting coatings
- Superior ionic conductivity from gel-polymer electrolytes loaded with nanoscale fillers
- Scalable, customizable fabrication through standalone or stacked electrospun layers
- Robust mechanical durability of fiber-based mats for long cycle life