Technology

Combining solid-state chemistry
with scalable roll-based manufacturing

Ensurge solid-state lithium battery (SSLB) technology combines advanced energy cell design with Ensurge’s proprietary materials and manufacturing innovation to produce amazingly thin and flexible batteries that can power safer and more capable hearables, wearables, and connected sensors.

These emerging applications demand innovative energy storage, and Ensurge SSLBs are designed to unleash designers’ creativity by removing the form factor limitations inherent in coin-cell, button-cell, and pouch-based alternatives while providing superior volumetric energy density and manufacturing scalability compared to other solid-state microbatteries.

Diagram of various layers of SSLB device

The Ensurge SSLB Difference

Ensurge SSLBs leverage fundamental materials and manufacturing advantages compared to other solid-state devices, enabling more powerful, durable, and reliable batteries.

Ensurge’s unique manufacturing capabilities on ultra-thin, large-area, flexible substrates enable SSLBs that exceed the performance of other solutions on the market. This state-of-the-art platform is based on its comprehensive roll-based fabrication line – located in the heart of Silicon Valley – and extensive patents and knowhow in flexible electronics manufacturing.

These capabilities enable a new class of batteries that are thinner and more flexible than coin cells, last longer than other SSLBs, and improve safety compared to lithium-ion alternatives.

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Energy Density

Superior energy density in ultracompact footprints

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Durability

More mechanically robust than ceramic substrates, more flexible than glass and silicon

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Reliability

Superior charge/discharge cycling capability

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Scalability

20-1000x manufacturing batch size compared to glass or silicon wafers

Why solid-state batteries?

As portable consumer electronics have increased in popularity and performance, lithium-ion batteries have rapidly replaced traditional rechargeable chemistries like nickel cadmium (NiCd) and nickel metal hydride (NiMH).

However, traditional lithium-ion batteries use a powerful but potentially dangerous combination of a liquid electrolyte and often fragile separator materials that can lead to leakage, fire, and even explosion. In aviation, US Federal Aviation Administration (FAA) reports a lithium-ion battery incident affecting airports, passenger flights, or cargo operations on a near-weekly pace. The US Fire Administration has attributed nearly 200 recent fires and explosions to malfunctioning lithium batteries. For consumer electronics, US Consumer Product Safety Commission lists millions of devices recalled due to lithium battery safety concerns. To avoid these problems, solid-state lithium batteries replace problematic materials with stable alternatives that won’t catch fire or explode.

In addition to improved safety, solid-state lithium batteries can be manufactured in a wide variety of shapes and sizes and – because they can be manufactured without a bulky pouch – enable significantly thinner end products. The materials and chemistry also reduce internal charge leakage, leading to improved battery life in long-duration, low-power applications.