Gap width modification on fully screen-printed coplanar Zn|MnO2 batteries

Fully printed primary zinc-manganese dioxide (Zn|MnO2) batteries in coplanar configuration were fabricated by sequential screen printing. While electrode dimensions and transferred active masses were kept at constant levels, electrode separating gaps were incrementally enlarged from 1 mm to 5 mm. Calendering of solely zinc anodes increased interparticle contact of active material within the electrodes while the porosity of manganese dioxide based electrodes was maintained by non-calendering. Chronopotentiometry revealed areal capacities for coplanar batteries up to 2.8 mAh cm−2. Galvanostatic electrochemical impedance spectroscopy measurements and short circuit measurements were used to comprehensively characterise the effect of gap width extension on bulk electrolyte resistance and charge transfer resistance values. Linear relationships between nominal gap widths, short circuit currents and internal resistances were evidenced, but showed only minor impact on actual discharge capacities. The findings contradict previous assumptions to minimise gap widths of printed coplanar batteries to a sub-millimetre range in order to retain useful discharge capacities. The results presented in this study may facilitate process transfer of printed batteries to an industrial environment