Conformal lithium polymer battery

• US 20070079500A1
• Filed: 10/10/2006
• Published: 04/12/2007
• Est. Priority Date: 10/10/2005
• Status: Active Grant

• Current Assignee: MB Research & Development, LLC
• Original Assignee: Martin Silverman
• Inventors: Silverman, Martin
• Granted Patent: US 7,780,745 B2
• Time in Patent Office: Days
• US Class Current: 29/623.100
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 50/533 characterised by the shape of the leads or tabs
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/536 characterised by the method of fixing the leads to the electrodes, e.g. by welding
• 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 29/49114 including adhesively bonding
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

This invention is a method of fabricating a conformal lithium polymer battery comprising the steps of: selecting a slab of lithium polymer battery material of a desired height, containing a desired number of cells; freezing the slab; vertically cutting the slab to a desired shape; attaching a lead to each anode conductor; and attaching a lead to a each cathode conductor. The slab may contain one or many cells. The leads may be made of multistranded, metallic wire, metallic ribbon, low melting point alloy, self-healing metal, and litz wire. Attachment is accomplished so as to minimize tension on the leads. The cut slab may need to be deburred after cutting and before attaching leads. Preferably, burr formation is prevented by recessing the edge of the anodic or cathodic half cells. Lead attachment my be accomplished by: wire bonding; wedge bonding; adhesive bonding with conductive epoxy, anistotropic conductive adhesive or conductive thermoplastic; stapling; adhering the lead to the electrode by electropolymerization; welding; and growing a lead in place by electroless plating, electro-plating or a combination of electroless plating and electroplating. The distal ends of the leads may be connected together so that the cells are connected together in series, in parallel or some in series and the remainder in parallel. After the leads have been attached to the cut slab and connected together, the assembly will preferably be wrapped with standard packaging for lithium polymer batteries.

Claims

1. A method of fabricating a conformal lithium polymer battery comprising the steps of:

a) selecting a slab of lithium polymer battery material of a desired height;

b) freezing said slab;

c) vertically cutting said slab to a desired shape thus forming a cut edge;

d) attaching a lead to an anode conductor of said cut slab along said cut edge while maintaining said cut slab frozen; and

e) attaching a lead to a cathode conductor of said cut slab along said cut edge while maintaining said cut slab frozen.

2. A method as claimed in claim 1 in which said lead is selected from the group consisting of multistranded, metallic wire, metallic ribbon, low melting point alloy, self-healing metal, and litz wire.

3. A method as claimed in claim 1 in which said lead attaching steps are accomplished so as to minimize tension on said leads.

4. A method as claimed in claim 1 further comprising the step of deburring said cut slab after cutting and before attaching leads.

5. A method as claimed in claim 1 further comprising the steps:

a) inspecting said cut edge for burrs; and

b) removing said burrs;

after cutting and before attaching leads.

6. A method as claimed in claim 1 further comprising the steps of:

a) recessing the edge of one half cell by mechanical means;

b) blowing away dust; and

c) insulating the recessed edge with non-conductive polymer.

7. A method as claimed in claim 1 in which said attaching step is accomplished by wire bonding.

8. A method as claimed in claim 1 in which said attaching step is accomplished by wedge bonding.

9. A method as claimed in claim 1 in which said attaching step is accomplished with conductive epoxy.

10. A method as claimed in claim 1 in which said attaching step is accomplished with conductive thermoplastic.

11. A method as claimed in claim 1 in which said attaching step is accomplished with microstaples.

12. A method as claimed in claim 1 in which said attaching step is accomplished by electropolymerization.

13. A method as claimed in claim 1 in which said attaching step is accomplished by micro welding.

14. A method as claimed in claim 1 in which said attaching step is accomplished with anistotropic conductive adhesive.

15. A method as claimed in claim 1 in which said attaching step is accomplished by electroless plating.

16. A method as claimed in claim 1 in which said attaching step is accomplished by electro-plating.

17. A method as claimed in claim 1 in which said attaching step is accomplished by a combination of electroless plating and electro-plating.

18. A method as claimed in claim 1 in which said leads are insulated.

19. A method as claimed in claim 1 in which said leads are insulated with thermoplastic insulator.

20. A method as claimed in claim 1 further comprising the step of wrapping said cut slab and attached leads with standard packaging for lithium polymer batteries.

21. A method of fabricating a conformal lithium polymer battery comprising the steps of:

a) selecting a slab of lithium polymer battery material of a desired height;

said slab containing a plurality of cells;

b) freezing said slab;

c) vertically cutting said slab to a desired shape thus forming a cut edge;

d) attaching an anode lead to each anode conductor of said cut slab along said cut edge while maintaining said cut slab frozen; and

e) attaching a cathode lead to a each cathode conductor of said cut slab along said cut edge while maintaining said cut slab frozen.

22. A method as claimed in claim 21 in which said leads are selected from the group consisting of multistranded, metallic wire, metallic ribbon, low melting point alloy, self-healing metal, and litz wire.

23. A method as claimed in claim 21 in which said lead attaching steps are accomplished so as to minimize tension on said leads.

24. A method as claimed in claim 21 further comprising the step of deburring said cut slab after cutting and before attaching leads.

25. A method as claimed in claim 21 further comprising the steps:

a) inspecting said cut edge for burrs; and

b) removing said burrs;

after cutting and before attaching leads.

26. A method as claimed in claim 21 further comprising the steps of:

a) recessing the edge of each anodic half cell or each cathodic half cell by mechanical means;

b) blowing away dust; and

c) insulating the recessed edges with non-conductive polymer.

27. A method as claimed in claim 21 in which said attaching step is accomplished by wire bonding.

28. A method as claimed in claim 21 in which said attaching step is accomplished by wedge bonding.

29. A method as claimed in claim 21 in which said attaching step is accomplished with conductive epoxy.

30. A method as claimed in claim 21 in which said attaching step is accomplished with conductive thermoplastic.

31. A method as claimed in claim 21 in which said attaching step is accomplished with microstaples.

32. A method as claimed in claim 21 in which said attaching step is accomplished by electropolymerization.

33. A method as claimed in claim 21 in which said attaching step is accomplished by micro welding.

34. A method as claimed in claim 21 in which said attaching step is accomplished with anistotropic conductive adhesive.

35. A method as claimed in claim 21 in which said attaching step is accomplished by electroless plating.

36. A method as claimed in claim 21 in which said attaching step is accomplished by electro-plating.

37. A method as claimed in claim 21 in which said attaching step is accomplished by a combination of electroless plating and electro-plating.

38. A method as claimed in claim 21 in which said leads are insulated.

39. A method as claimed in claim 21 in which said leads are insulated with thermoplastic insulator.

40. A method as claimed in claim 21 further comprising the steps of:

a) electrically connecting the distal ends of said anodic leads together; and

b) electrically connecting the distal ends of said cathodic leads together;

whereby the cells of said cut slab are connected together in parallel.

41. A method as claimed in claim 21 further comprising the step of electrically connecting the distal end of each anodic lead and the distal end of said cathodic lead so that the cells of said cut slab are connected together in series.

42. A method as claimed in claim 21 further comprising the step of electrically connecting the distal end of each anodic lead and the distal end of said cathodic lead so that some of the cells of said cut slab are connected together in series and the remainder of cells is connected together in parallel.

43. A method as claimed in claim 40 further comprising the step of wrapping said cut slab and attached leads with standard packaging for lithium polymer batteries.

44. A method as claimed in claim 41 further comprising the step of wrapping said cut slab and attached leads with standard packaging for lithium polymer batteries.

45. A method as claimed in claim 42 further comprising the step of wrapping said cut slab and attached leads with standard packaging for lithium polymer batteries.