Flexible Batteries: The Future of Smart Packaging and Wearables

Flexible solar cells
Flexible batteries are a niche technology which can be achieved through various battery chemistries and structures, with their main applications targeted within smart labels and wearables markets. IDTechEx's newly released report, "Flexible Batteries Market 2025-2035: Technologies, Forecasts, and Players", explores predictions for the flexible battery market alongside new opportunities for the companies operating within the industry.
 
Applications within the flexible battery market
 
Smart labels and logistics are one of the main applications for flexible batteries, powering the sensors that measure the temperature of products and the freshness of food to ensure high product quality. The wearables sector also utilizes up-and-coming flexible battery technology, particularly in smaller and more intricate products such as smart rings and bracelets, where the battery can be fitted in around the design without the need for extra bulk.
 
Pre-wrinkled packaging and electrolytes
 
Flexibility is more easily achieved with extremely thin batteries, where there is less stress applied to the components when they are bent. One of the biggest barriers to flexibility, alongside certain battery chemistries, is rigid packaging. When normal cells are bent, creases that form in the packaging material could form sharp points, which, over time, could puncture the components within the battery. Through the process of pre-wrinkling, the areas where wrinkles form during flexing can be predetermined. This reduces the risk of component puncture, allowing for more movement overall.
 
Liquid electrolyte is not an ideal choice for flexible batteries, as it is much more flammable than alternatives, and could combust if a battery were to break, assigning extra importance to the outer packaging. Larger batteries that are less thin could use solid-state electrolytes to provide a greater safety factor despite the increased costs, while semi-solid electrolytes, resembling a gel-like consistency, could be another potential alternative for flexible batteries.
 
Flexible battery chemistries
 
Thin batteries such as thin-film solid-state, printed zinc chemistries, and primary lithium were some of the first to mature, allowing for greater safety than other flexible battery options. Thin-film solid-state offers the greatest safety but at very steep costs compared to other thin, flexible options, and rigid options. However, they matured earlier and proved to be much safer than other flexible battery options, meaning they are a good candidate for high-end applications or where great reliability is necessary. Bulk solid-state batteries can still achieve flexibility with their use of solid-state electrolytes, and despite being larger than thin-film options, are still smaller than regular batteries.
 
While traditional Li-ion batteries are not ideal for bending due to the risk of the liquid electrolyte leaking or components separating, advanced Li-ion batteries use a different electrolyte and pre-wrinkled packaging to ensure that the components are safer and that the adhesive is not likely to break. Coin cells are one of the main battery chemistries competing with thin flexible batteries, as despite being inflexible, they are easy and low-cost to manufacture, as well as being small enough to fit into a variety of products, potentially eradicating a large proportion of potential applications for flexible batteries.
 
Hype vs reality within the market
 
The cost and lack of general interest in flexible battery technologies means the scope for large development is limited. The hype around potential flexible phones and other smart products may gain traction. However, the feasibility of developing such products with high material and development costs cannot quite match up. IDTechEx's latest report, "Flexible Batteries Market 2025-2035: Technologies, Forecasts, and Players", explores applications within smart packaging and wearables, as well as trends and predictions for flexible batteries across the next 10 years.
 
To find out more about this IDTechEx report, including downloadable sample pages, please visit www.IDTechEx.com/flex.
 
For the full portfolio of energy storage and batteries market research available from IDTechEx, please see www.IDTechEx.com/Research/ES.

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