Thin printable electrochemical cell utilizing a "picture frame" and methods of making the same

• US 20060216586A1
• Filed: 03/17/2006
• Published: 09/28/2006
• Est. Priority Date: 03/22/2005
• Status: Active Grant

• Current Assignee: Blue Spark Innovations LLC
• Original Assignee: Blue Spark Technologies, Inc.
• Inventors: Tucholski, Gary R.
• Granted Patent: US 8,029,927 B2
• Time in Patent Office: Days
• US Class Current: 429/162
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/365 Zinc-halogen accumulators
• 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: H01M 12/085 Zinc-halogen cells or batteries
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• CPC Class Codes: H01M 4/42 Alloys based on zinc
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/663 containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 50/105 Pouches or flexible bags
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/126 comprising three or more layers
• CPC Class Codes: H01M 50/133 Thickness
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/193 Organic material
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: H01M 6/42 : Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H01M 6/46 : of flat cells
• 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
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating

Abstract

A thin printed flexible electrochemical cell, and its method of manufacture, using a “picture frame” structure sealed, for example, with a high moisture and oxygen barrier polymer film and featuring, for example, a printed cathode deposited on an optional, highly conductive carbon printed cathode collector with a printed or a foil strip anode placed adjacent to the cathode. A viscous or gelled electrolyte is dispensed and/or printed in the cell, and a top laminate can then be sealed onto the picture frame. Such a construction could allow the entire cell to be made on a printing press, for example, as well as gives the opportunity to integrate the battery directly with an electronic application, for example.

Claims

1. A device comprising a flat, thin electrochemical cell for generating an electrical current, said cell including:

a first substrate layer;

a second substrate layer;

a cathode layer provided on at least one of said first substrate layer and said second substrate layer;

an anode layer provided on at least one of said first substrate layer and said second substrate layer;

an electrolyte layer in contact with said cathode layer and also in contact with said anode layer; and

a frame provided substantially around a perimeter of said cell and connecting said lower substrate layer to said upper substrate layer, wherein

said frame is substantially thicker than each one of said cathode layer, said anode layer, and said electrolyte layer.

2. The device of claim 1, wherein said frame is comprised of a laminated polyester sheet having two adhesive layers, one on each side of said frame, said adhesive layer for adhesively connecting said lower substrate layer to said upper substrate layer.

3. The device of claim 2, wherein said adhesive layers utilize a release liner prior to the construction of said device.

4. The device of claim 1, further comprising a cathode collector layer provided between said substrate and said cathode layer.

5. The device of claim 4, wherein one or both of said anode layer and said cathode layer are comprised of a dried or cured ink.

6. The device of claim 5, wherein only one of said cathode layer and said anode layer is comprised of a dried or cured ink, and wherein the other of said cathode layer and said anode layer is comprised of a strip of material.

7. The device of claim 6, wherein said strip of material includes zinc.

8. The device of claim 6, where said strip of material is a laminate including an adhesive layer.

9. The device of claim 8, wherein said strip of material includes zinc.

10. The device of claim 1, wherein said frame is located around a perimeter of said cell.

11. The device of claim 10, wherein said frame provides means of accessing one or both of said cathode layer and said anode layer through said frame.

12. The device of claim 11, wherein said means of accessing is comprised of through-holes through said frame, and wherein said cell further comprises an adhesive layer for sealing said frame to one or both of said lower substrate layer and said upper substrate layer, said adhesive layer also for sealing said through-holes.

13. The device of claim 10, said cell further comprising an adhesive layer for sealing said frame to one or both of said lower substrate layer and said upper substrate layer.

14. The device of claim 13, wherein said adhesive layer is comprised of a sealing caulk.

15. The device of claim 1, wherein

said frame is about as thick as the sum of a thickness of said electrolyte and at least one of said anode layer and said cathode layer, and wherein

said device is substantially flat and of a thickness of about that of the thickness of said frame added to the thickness of each of said substrate layers.

16. The device of claim 1, wherein one or both of said first substrate layer and said second substrate layer are comprised of a laminate of a plurality of different layers.

17. The device of claim 16, wherein said different layers include a metalized layer.

18. The device of claim 16, wherein said different layers include a structural layer, an oxide barrier layer, and a heat sealing layer.

19. The device of claim 1, further comprising an electronic component formed concurrently with said cell.

20. The device of claim 1, further comprising a plurality of said cells electrically connected together to form a substantially flat battery.

21. The device of claim 20, wherein said plurality of cells share at least a portion of the same frame.

22. The device of claim 1, wherein said anode layer and said cathode layer are both provided on the same one of said first substrate layer and said second substrate layer, such that said anode layer and said cathode layer are substantially co-planar.

23. The device of claim 1, wherein said anode layer and said cathode layer are arranged in a co-facial manner.

24. The device of claim 1, wherein said anode layer and said cathode layer are arranged in a co-planar manner.

25. The device of claim 1, wherein said frame, along with said first substrate layer and said second substrate layer, form a sealed inner space containing said electrolyte layer, comprising a gel or liquid, within said cell.

26. The device of claim 25, wherein said inner space also contains at least a majority of said cathode layer and said anode layer within said space.

27. The device of claim 1, wherein said frame is comprised of an ink.

28. The device of claim 1, wherein said frame is comprised of a UV cured dielectric material.

29. A device comprising a flat electrochemical cell for generating an electrical current, said cell including:

a first substrate layer comprised of a plurality of laminated layers;

a second substrate layer;

a cathode layer provided on at least one of said first substrate layer and said second substrate layer;

an anode layer provided on at least one of said first substrate layer and said second substrate layer;

an electrolyte layer comprising a viscous liquid in contact with said cathode layer and also in contact with said anode layer; and

a frame connecting and sealing said lower substrate layer to said upper substrate layer to form an inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space, wherein

at least one of said anode layer and said cathode layer are comprised of a cured or dried ink.

30. The device of claim 29, wherein only one of said cathode layer and said anode layer is comprised of a dried or cured ink, and wherein the other of said cathode layer and said anode layer is comprised of a strip of material.

31. The device of claim 29, wherein said frame provides means of accessing one or both of said cathode layer and said anode layer through said frame.

32. The device of claim 29, further comprising an electronic component manufactured concurrently with said cell.

33. The device of claim 29, further comprising a plurality of said cells electrically connected together to form a battery.

34. The device of claim 29, wherein said anode layer and said cathode layer are both provided on the same one of said first substrate layer and said second substrate layer and wherein said anode layer and said cathode layer are substantially co-planar.

35. The device of claim 34, wherein only one of said cathode layer and said anode layer is comprised of a dried or cured ink, and wherein the other of said cathode layer and said anode layer is comprised of a strip of material.

36. The device of claim 29, wherein said device is formed into a substantially flat shape of a thickness about that of the thickness of said frame added to the thickness of each of said substrate layers.

37. The device of claim 29, wherein one or both of said substrate layers include all of a structural layer, an oxide barrier layer, and a heat sealing layer.

38. The device of claim 29 wherein one or both of (1) a cathode collector layer is provided between said cathode layer and said at least one of said first substrate layer and said second substrate layer upon which said cathode layer is provided;

and (2) an anode collector layer is provided between said anode layer and said at least one of said first substrate layer and said second substrate layer upon which said anode layer is provided.

39. The device of claim 29, further comprising a separator layer for keeping both said anode layer and said cathode layer wet with said electrolyte.

40. The device of claim 29, wherein said anode layer and said cathode layer are arranged in a co-facial manner.

41. The device of claim 29, wherein said anode layer and said cathode layer are arranged in a co-planar manner.

42. A battery comprising at least one cell, said at least one cell including:

a first substrate layer comprised of a plurality of laminated layers including at least a structural layer, an oxide barrier layer, and a sealing layer;

a second substrate layer comprised of said plurality of laminated layers;

a cathode collector layer provided on at least one of said first substrate layer and said second substrate layer;

a cathode layer provided on said cathode collector layer;

an anode layer provided on at least one of said first substrate layer and said second substrate layer or provided on an anode collector layer provided on at least one of said first substrate layer and said second substrate layer;

an electrolyte layer including an electrolyte in contact with said anode layer and said cathode layer; and

a frame around a perimeter of said cell for connecting said lower substrate layer to said upper substrate layer to form an inner space for containing said electrolyte within said inner space along with at least a portion of said anode layer and at least a portion of said cathode layer, wherein

said inner space is substantially sealed off from an exterior of said cell.

43. The battery of claim 42, wherein said electrolyte layer includes a separator layer for keeping both said anode layer and said cathode layer wet with said electrolyte.

44. The battery of claim 42, wherein said electrolyte layer includes a means for forming said electrolyte layer into a viscous liquid in contact with said anode layer and said cathode layer.

45. The battery of claim 42, wherein said cathode layer is comprised of an ink.

46. The battery of claim 45, wherein said cathode collector layer is comprised of a different ink.

47. The battery of claim 46, wherein said anode layer is comprised of a strip including zinc.

48. The battery of claim 42, where at least a portion of said collector layer faces at least a portion of said anode layer.

49. The battery of claim 42, wherein said anode layer is substantially coplanar with, and adjacent to, said cathode layer.

50. The battery of claim 42, wherein said frame includes:

an inner frame; and

an outer frame, wherein

a frame space is formed between said inner frame and said outer frame.

51. The battery of claim 50, wherein said frame space is sealed for containing said electrolyte within said cell should said inner frame develop a leak.

52. The battery of claim 42, wherein said cathode layer includes an ink having a polymer binder including one or more of polyvinylpyrrolidone, polyvinyl alcohol, a starch, a modified starch, ethyl cellulose, hydroxy-ethyl cellulose, methyl cellulose, polyethylene oxide, polyacryamide, and Teflon.

53. A label comprising the battery of claim 42 and further comprising an adhesive layer.

54. A medical device comprising the battery of claim 42.

55. A method of manufacturing a device including an electrochemical cell, said method comprising the step of forming said cell, said forming including the steps of:

providing a first substrate layer and a second substrate layer, at least one of which including a laminated web having a plurality of layers;

printing one of a cathode layer and an anode layer on one of said first substrate layer and said second substrate layer;

providing, by printing or some other process, the other of said cathode layer and said anode layer on one of said first substrate layer and said second substrate layer;

providing a frame on one of said first substrate layer and said second substrate layer;

providing an electrolyte layer, said electrolyte layer comprising a viscous liquid; and

connecting the other of said first substrate layer and said second substrate layer to said frame to form an inner substantially sealed space containing said cathode layer, said anode layer, and said electrolyte layer.

56. The method of claim 55, further comprising the step of forming an electrically powered component, concurrent with the forming of said cell, wherein said component is included in said device.

57. The battery of claim 55, wherein said frame is printed on said one of said first substrate layer and said second substrate layer.