Biomedical energization elements with polymer electrolytes and cavity structures

• US 10,367,233 B2
• Filed: 02/28/2018
• Issued: 07/30/2019
• Est. Priority Date: 08/21/2014
• Status: Expired due to Fees

• Current Assignee: Johnson & Johnson Vision Care Incorporated (Johnson & Johnson)
• Original Assignee: Johnson & Johnson Vision Care Incorporated (Johnson & Johnson)
• Inventors: Flitsch, Frederick A., Muthu, Millburn Ebenezer Jacob, Otts, Daniel B., Pugh, Randall B., Riall, James Daniel, Toner, Adam
• Primary Examiner(s): Marks, Jacob B
• Application Number:
  US15/907,621
• Publication Number:
  US 20180191035A1
• Time in Patent Office: 517 Days
• CPC Class Codes: B29D 11/00038 Production of contact lenses
• CPC Class Codes: B29D 11/00817 Producing electro-active lenses or lenses with energy receptors, e.g. batteries or antennas
• CPC Class Codes: G02C 7/04 Contact lenses for the eyes disinfection or sterilisation of contact lenses A61L12/00
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/26 Selection of materials as electrolytes
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 2300/0014 Alkaline electrolytes
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 4/06 Electrodes for primary cells
• CPC Class Codes: H01M 4/38 of elements or alloys
• CPC Class Codes: H01M 4/502 for non-aqueous cells H01M4/505 takes precedence
• CPC Class Codes: H01M 6/181 with polymeric electrolytes
• 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

Designs, strategies and methods to form energization elements comprising polymer electrolytes are described. In some examples, the biocompatible energization elements may be used in a biomedical device. In some further examples, the biocompatible energization elements may be used in a contact lens.

Claims

1. A method of manufacturing a battery comprising:

obtaining a cathode collector film, wherein the cathode contact film comprises titanium;

coating the cathode collector film with a carbon coating;

obtaining a first laminate layer, wherein the first laminate layer comprises a first body and at least a first release layer and pressure sensitive adhesive upon surfaces of the body;

cutting a hole in the first laminate layer;

adhering the cathode collector film with the carbon coating to the first laminate layer, wherein the hole in the first laminate layer and the cathode collector film with carbon coating create a first cavity;

depositing a transition metal oxide slurry into the first cavity and upon the carbon coating;

drying the transition metal oxide deposit;

obtaining a second laminate layer, wherein the second laminate layer comprises a second body and at least a second release layer and pressure sensitive adhesive upon surfaces of the second body;

cutting a hole in the second laminate layer;

adhering a metal foil to the second laminate layer, wherein the hole in the second laminate layer and the metal foil create a second cavity;

depositing a polymer electrolyte comprising ionic constituents into the second cavity;

drying the polymer electrolyte;

laminating the first laminate layer to the second laminate layer, wherein the first cavity and the second cavity align at least in a respective portion and the polymer electrolyte and the transition metal oxide deposit are laminated together;

cutting material from the laminate layers in a region peripheral to the first cavity and the second cavity;

encapsulating the metal foil, polymer electrolyte, transition metal oxide deposit, cathode collector, first laminate layer and second laminate layer in a biocompatible encapsulating film; and

singulating a battery element from the encapsulated metal foil, polymer electrolyte, transition metal oxide deposit, and cathode collector in a biocompatible encapsulating film.

2. The method of claim 1, wherein the transition metal oxide comprises manganese wherein the metal foil comprises zinc;

and wherein the ionic constituents comprises zinc.

3. The method of claim 2, wherein the singulated battery element has a thickness is less than 1 mm at least along a first dimension of the extents of the singulated battery element.

4. The method of claim 2, wherein the singulated battery element has a thickness is less than 500 microns at least along a first dimension of the extents of the singulated battery element.

5. The method of claim 2, wherein the singulated battery element has a thickness is less than 250 microns at least along a first dimension of the extents of the singulated battery element.

6. The method of claim 2, wherein the shape of the singulated battery element is curvilinear.

7. A method of energizing a biomedical device comprising:

obtaining a cathode collector film, wherein the cathode contact film comprises titanium;

coating the cathode collector film with a carbon coating;

obtaining a first laminate layer, wherein the first laminate layer comprises a first body and at least a first release layer and pressure sensitive adhesive upon surfaces of the body;

cutting a hole in the first laminate layer;

adhering the cathode collector film with the carbon coating to the first laminate layer, wherein the hole in the first laminate layer and the cathode collector film with carbon coating create a first cavity;

depositing a manganese dioxide slurry into the first cavity and upon the carbon coating;

drying the manganese dioxide deposit;

obtaining a second laminate layer, wherein the second laminate layer comprises a second body and at least a second release layer and pressure sensitive adhesive upon surfaces of the second body;

cutting a hole in the second laminate layer;

adhering a zinc foil to the second laminate layer, wherein the hole in the second laminate layer and the zinc foil create a second cavity;

depositing a polymer electrolyte comprising ionic constituents into the second cavity;

drying the polymer electrolyte;

laminating the first laminate layer to the second laminate layer, wherein the first cavity and the second cavity align at least in a respective portion and the polymer electrolyte and the manganese dioxide deposit are laminated together;

cutting material from the laminate layers in a region peripheral to the first cavity and the second cavity;

encapsulating the zinc foil, polymer electrolyte, manganese dioxide deposit, cathode collector, first laminate layer and second laminate layer in a biocompatible encapsulating film;

connecting the anode current collector to an electroactive device;

connecting the cathode current collector to the electroactive device;

encapsulating the laminar structure and electroactive device in a second biocompatible encapsulating layer to form a biomedical device.