Stretchable printed battery and methods of making

• US 10,003,087 B1
• Filed: 12/08/2014
• Issued: 06/19/2018
• Est. Priority Date: 12/09/2013
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Liu, Weifeng, Pang, Dick Tak Shing, Mohammed, Anwar, Kurwa, Murad
• Primary Examiner(s): Chmielecki, Scott J
• Application Number:
  US14/563,885
• Time in Patent Office: 1,289 Days
• Field of Search: None
• CPC Class Codes: A41D 1/002 adapted to accommodate electronic equipment patients' garments for medical monitoring A41D13/1281; luminous ornaments A41D27/085
• CPC Class Codes: A41D 1/005 with embedded cable or connector
• CPC Class Codes: D05B 17/00 Sewing machines for concurrently making thread and welded seams for making non-welded fluid-tight seams D05B1/26
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: H01R 4/00 Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
• CPC Class Codes: H01R 4/02 Soldered or welded connections H01R4/625, H01R4/723, H01R12/59 take precedence
• CPC Class Codes: H01R 4/029 Welded connections H01R4/021 - H01R4/028 take precedence
• CPC Class Codes: H01R 43/005 for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
• CPC Class Codes: H01R 43/02 for soldered or welded connections
• CPC Class Codes: H01R 43/0235 for applying solder H01R43/0228 takes precedence
• CPC Class Codes: H05K 1/0271 Arrangements for reducing stress or warp in rigid printed circuit boards, e.g. caused by loads, vibrations or differences in thermal expansion
• CPC Class Codes: H05K 1/0296 Conductive pattern lay-out details not covered by sub groups H05K1/02 - H05K1/0295 H05K1/11 takes precedence; lay-out adapted to mounted component configuration H05K1/18
• CPC Class Codes: H05K 1/0298 Multilayer circuits
• CPC Class Codes: H05K 1/0306 Inorganic insulating substrates, e.g. ceramic, glass
• CPC Class Codes: H05K 1/0366 reinforced, e.g. by fibres, fabrics H05K1/036 takes precedence
• CPC Class Codes: H05K 1/0373 containing additives, e.g. fillers H05K1/036 takes precedence
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 1/09 : Use of materials for the conductive, e.g. metallic pattern
• CPC Class Codes: H05K 1/11 : Printed elements for providing electric connections to or between printed circuits
• CPC Class Codes: H05K 1/111 : Pads for surface mounting, e.g. lay-out
• CPC Class Codes: H05K 1/112 : directly combined with via connections
• CPC Class Codes: H05K 1/115 : Via connections; Lands around holes or via connections H05K1/112 takes precedence
• CPC Class Codes: H05K 1/18 : Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 1/181 : associated with surface mounted components
• CPC Class Codes: H05K 1/189 : characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 13/04 : Mounting of components , e.g. of leadless components
• CPC Class Codes: H05K 2201/0154 : Polyimide
• CPC Class Codes: H05K 2201/0158 : Polyalkene or polyolefin, e.g. polyethylene [PE], polypropylene [PP]
• CPC Class Codes: H05K 2201/0162 : Silicon containing polymer, e.g. silicone
• CPC Class Codes: H05K 2201/0287 : Unidirectional or parallel fibers
• CPC Class Codes: H05K 2201/05 : Flexible printed circuits [FPCs]
• CPC Class Codes: H05K 2201/09418 : Special orientation of pads, lands or terminals of component, e.g. radial or polygonal orientation
• CPC Class Codes: H05K 3/284 : for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: H05K 3/30 : Assembling printed circuits with electric components, e.g. with resistor
• CPC Class Codes: H05K 3/305 : Affixing by adhesive
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: H05K 3/4015 : using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres
• CPC Class Codes: H05K 3/42 : Plated through-holes or plated via connections
• CPC Class Codes: H05K 3/4644 : by building the multilayer layer by layer, i.e. build-up multilayer circuits making via holes in the insulating layers H05K3/0011; special circuit boards as base or core whereon the multilayer is built H05K3/4602
• CPC Class Codes: H05K 7/02 : Arrangements of circuit components or wiring on supporting structure
• CPC Class Codes: H05K 9/009 : comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

A stretchable battery and the method of manufacturing the same. The stretchable battery can be manufactured by using a printing process. The construction of the stretchable battery can comprise a first layer of an elastomer film, a first current collector layer, a layer of cathode, a separating layer, a layer of anode, and a second current collector layer. Metal traces can be used to couple with the first and/or the second current collector layers.

Claims

1. A battery comprising a stretchable body, wherein the stretchable body includes:

an energy source portion; and

two sealing portions sandwiching the energy source portion, wherein each of the sealing portion includes an external elastomer cover and internal metal sealing layer that is lengthwise sized smaller than the external elastomer cover such that the internal metal sealing layer is enclosed within the stretchable body by ends of the external elastomer cover extending beyond ends of the internal metal sealing layer and sealing over the ends of the internal metal sealing layer.

2. The battery of claim 1, wherein the stretchable body comprises a first current collector layer, a cathode layer, a solid electrolyte layer, an anode layer, and a second current collector layer.

3. The battery of claim 2, wherein the solid electrolyte layer covers an entire area of the cathode layer, such that the solid electrolyte layer prevents the anode layer from contacting the cathode layer.

4. The battery of claim 1, wherein the stretchable body couples with one or more conductive traces.

5. The battery of claim 1, wherein the stretchable body is patterned in a non-linear shape.

6. The battery of claim 5, wherein the non-linear shape comprises a re-occurring pattern.

7. The battery of claim 1, wherein the stretchable body is stretchable in a plane.

8. The battery of claim 1, wherein the stretchable body is on an elastomer film.

9. A battery comprising a stretchable body, wherein the stretchable body includes:

a structure that includes a first current collector layer, a cathode layer, a solid electrolyte layer, an anode layer, and a second current collector layer; and

two sealing portions sandwiching the structure, wherein each sealing portion includes an external elastomer cover and an internal metal sealing layer that interfaces the structure, includes sintered nano-metal materials and is enclosed within the stretchable body by the external elastomer cover.

10. The battery of claim 9, wherein the second current collector layer is positioned on top of the anode layer, which is positioned on top of the solid electrolyte layer, which is positioned on top of the cathode layer, which is positioned on top of the first current collector layer.

11. The battery of claim 10, wherein the first and second current collector layers each includes conductive ink.

12. The battery of claim 11, wherein each layer in the structure is a printed layer on the bottommost external elastomer cover.

13. The battery of claim 12, wherein the solid electrolyte layer fully covers the cathode layer.

14. The battery of claim 13, wherein the two sealing portions encapsulate the structure.

15. The battery of claim 14, further comprising non-conductive sealing material covering the ends of the structure.

16. The battery of claim 15, further comprising a first set of electronic circuit traces coupling with the first current collector layer, wherein a first portion of the first set of electronic circuit traces couple with one end of the of the first current collector layer, and wherein a second portion of the first set of electronic circuit traces couple with another end of the of the first current collector layer that is opposite the one end of the of the first current collector layer.

17. The battery of claim 16, further comprising a second set of electronic circuit traces coupling with the second current collector layer, wherein a first portion of the second set of electronic circuit traces couple with one end of the of the second current collector layer, and wherein a second portion of the second set of electronic circuit traces couple with another end of the of the second current collector layer that is opposite the one end of the of the second current collector layer.

18. A battery comprising a stretchable body, wherein the stretchable body includes:

a structure that includes a first current collector layer, a cathode layer, a solid electrolyte layer, an anode layer, and a second current collector layer; and

two sealing portions sandwiching the structure, wherein each sealing portion includes an external elastomer cover and an internal metal sealing layer that interfaces the structure, wherein the metal sealing layer includes sintered nano-metal materials.

19. The battery of claim 18, wherein the second current collector layer is positioned on top of the anode layer, which is positioned on top of the solid electrolyte layer, which is positioned on top of the cathode layer, which is positioned on top of the first current collector layer.

20. The battery of claim 18, wherein the first and second current collector layers each includes conductive ink.