Device including flexible battery and method of producing same

• US 20040018422A1
• Filed: 07/24/2002
• Published: 01/29/2004
• Est. Priority Date: 07/24/2002
• Status: Abandoned Application

• Current Assignee: Philip Morris USA Incorporated (Altria Group, Inc.)
• Original Assignee: Philip Morris USA Incorporated (Altria Group, Inc.)
• Inventors: Austin, Dennis A., Sweeney, William Randolph, Lilly, Arnys Clifton, Islam, Quazi Towhidul
• Application Number:
  US10/201,272
• Publication Number:
  US 20040018422A1
• Time in Patent Office: Days
• US Class Current: 429/127
• CPC Class Codes: H01M 10/04 Construction or manufacture in general H01M10/058, H01M10/12, H01M10/28, H01M10/38 take precedence
• CPC Class Codes: H01M 10/0404 Machines for assembling batteries
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• 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
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

The present invention is a device including a flexible battery and the method of producing the device. The device is produced by a method similar to gravure printing. Various layers such as battery layers, solar cell layers, active display layers, conductive layers, electronic layers, and semiconductor layers may be combined using adhesion, or similar processes. The devices of the invention may be printed on various polymers or other suitable materials providing low-cost, high-yield production capabilities. The device may then be formed into a variety of useful items, such as signs, packaging, casing, or other desirable forms.

Claims

1. A flexible, multi-layered, interactive battery comprising:

a printed, polymeric semiconductor layer adjoined with a thin, flexible battery layer comprising;

a cathode sublayer,

an anode sublayer,

at least one electrolyte sublayer disclosed between said cathode and anode sublayers, and

wherein said layers are enclosed by an outer barrier layer.

2. The interactive battery of claim 1, further comprising a barrier layer.

3. The interactive battery of claim 1, wherein said battery layer comprises a polymer battery layer.

4. The interactive battery of claim 1, wherein said battery layer comprises a primary battery layer.

5. The interactive battery of claim 1, wherein said battery layer comprises a secondary battery layer.

6. The interactive battery of claim 5, wherein said battery layer comprises a lithium-ion (Li-ion) battery layer.

7. The interactive battery of claim 5, wherein said battery layer comprises a nickel cadmium (Ni—

Cd) battery layer.

8. The interactive battery of claim 5, further comprising a solar cell layer operatively connected to said battery layer.

9. The interactive battery of claim 1, further comprising an electronic device layer.

10. The interactive battery of claim 9, wherein said electronic device layer comprises an output device.

11. The interactive battery of claim 10, wherein said output device comprises a display device.

12. The interactive battery of claim 11, wherein said display device comprises an active display device.

13. The interactive battery of claim 12, wherein said active display device is an electrophoretic display device.

14. The interactive battery of claim 12, wherein said active display device is a twisting ball display device.

15. The interactive battery of claim 12, wherein said active display device comprises an electrocapillary display device.

16. The interactive battery of claim 11, wherein said display device comprises an LCD device.

17. The interactive battery of claim 11, wherein said display device comprises an LED display device.

18. The interactive battery of claim 10, wherein said output device comprises an emitter.

19. The interactive battery of claim 18, wherein said emitter is configured to emit radiation.

20. The interactive battery of claim 19, wherein said radiation comprises radio frequency (RF) radiation.

21. The interactive battery of claim 19, wherein said radiation comprises infrared (IR) radiation.

22. The interactive battery of claim 18, wherein said emitter is configured to emit audio signals.

23. The interactive device of claim 9, wherein said electronic device comprises an input device.

24. The interactive battery of claim 23, wherein said input device comprises a receiver.

25. The interactive battery of claim 24, wherein said receiver is configured to receive radiation.

26. The interactive battery of claim 25, wherein said radiation is RF radiation.

27. The interactive battery of claim 25, wherein said radiation is IR radiation.

28. The interactive battery of claim 24, wherein said receiver is configured to receive audio signals.

29. The interactive battery of claim 23, wherein said input device comprises a sensor.

30. The interactive battery of claim 1, wherein windows between non-adjacent layers are provided, and the non-adjacent layers are electrically connected through said windows.

31. The interactive battery of claim 9, further comprising at least one conductive layer disposed adjacent to said device layer.

32. The interactive battery of claim 1, wherein two, non-adjacent layers are electrically connected through a removed portion of any interposing layers.

33. A method for making a multi-layered, interactive battery by a web process comprising the steps of:

providing a flexible battery layer taken from an unwind roll which provides tension to the battery layer;

using the battery layer as a substrate;

adjoining one or more sub-layers to the battery layer by transfer and adhesion at individual processing rolls;

laminating additional layers and said battery layers together to provide an outer, protective layer.

34. The method of claim 33, wherein said battery layer comprises a polymer battery layer, and said method includes using said polymer battery layer as a substrate.

35. The method of claim 33, wherein said battery layer comprises a primary battery layer, and said method includes using said primary battery layer as a substrate.

36. The method of claim 33, wherein said battery layer comprises a secondary battery layer, and said method includes using said secondary battery layer as a substrate.

37. The method of claim 33, wherein said additional layers comprise a semiconductor layer, and said method includes laminating said semiconductor layer together with said battery layer.

38. The method of claim 33, wherein said semiconductor layer comprises a polymeric semiconductor layer, and said method includes laminating said polymeric semiconductor layer together with battery layer.

39. The method of claim 33, wherein said semiconductor layer is printed utilizing web processing techniques, and said method includes printing said semiconductor layer on the substrate formed by said batter layer.

40. The method of claim 33, wherein said additional layers comprise an electronic device layer, and said method includes laminating said electronic device layer together with said battery layer.

41. The method of claim 40, wherein said electronic device layer comprises a display, and said method includes laminating said display together with said battery layer.

42. The method of claim 41, wherein said display comprises an active display, and said method includes laminating said active display together with said battery layer.

43. The method of claim 42, wherein said active display comprises an electrophoretic display device, an electrocapillary display device, a gyricon display device, or a twisting ball display device, and said method includes laminating said active display together with said battery layer.

44. The method of claim 33, wherein said additional layers comprise a conductive layer, and said method includes laminating said conductive layer together with said battery layer.

45. The method of claim 33, wherein said additional layers comprise a solar cell layer, and said method includes laminating said solar cell layer together with said battery layer.

46. The method of claim 33, further comprising the step of creating electrical connections between two non-adjacent layers by removing a portion of any layers disposed between the two layers and pressing together the two layers.