METAL FILM ENCAPSULATION

• US 20070202395A1
• Filed: 03/16/2007
• Published: 08/30/2007
• Est. Priority Date: 08/09/2002
• Status: Active Grant

• Current Assignee: Sapurast Research LLC
• Original Assignee: Infinite Power Solutions, Inc. (Apple Inc.)
• Inventors: Snyder, Shawn, Neudecker, Bernd, Brantner, Paul
• Granted Patent: US 8,236,443 B2
• Time in Patent Office: Days
• US Class Current: 429/160
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0562 Solid materials
• 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 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

The present invention relates to metal foil encapsulation of an electrochemical device. The metal foil encapsulation may also provide contact tabs for the electrochemical device. The present invention may also include a selectively conductive bonding layer between a contact and a cell structure.

Claims

1. A battery comprising:

a first electrical contact;

a bonding layer coupled with said first electrical contact and comprising an embedded conductor;

at least one cell structure; and

a second electrical contact,

wherein said bonding layer and said at least one cell structure are sandwiched between said first and second contact layers.

2. The battery of claim 1, wherein said bonding layer is selectively conductive through said embedded conductor.

3. The battery of claim 1, wherein said cell structure is in selective electrical contact with said first electrical contact via said embedded conductor.

4. The battery of claim 1, wherein said first electrical contact further comprises an encapsulate metal.

5. The battery of claim 1, wherein said second electrical contact further comprises a substrate.

6. The battery of claim 1, wherein said bonding layer comprises a material selected from the group comprising an adhesive material, an insulating material, plastic, glass, KEVLAR®

, reinforcement materials, and fiberglass.

7. The battery of claim 1, wherein said conductor is selected from the group consisting of a tab, a wire, multiple wires, a wire mesh, perforated metal, a metal coating applied to the adhesive layer, and a disk.

8. The battery of claim 1, wherein said conductor is woven within said bonding layer.

9. The battery of claim 8, wherein said bonding layer comprises a slit within which said embedded conductor is woven.

10. The battery of claim 1, wherein said second contact comprises a material selected from the group consisting of gold, platinum, stainless steel, titanium, zirconium, cobalt, aluminum, indium, nickel, copper, silver, carbon, bronze, brass, beryllium, and oxides, nitrides, and alloys thereof.

11. The battery of claim 1, wherein said conductor comprises a material selected from the group consisting of gold, platinum, stainless steel, titanium, zirconium, cobalt, aluminum, indium, nickel, copper, silver, carbon, bronze, brass, beryllium, and oxides, nitrides, and alloys thereof.

12. The battery of claim 1 further comprising an insulating layer on said first contact.

13. The battery of claim 12 wherein said insulating layer comprises plastic.

14. The battery of claim 1 further comprising an insulating layer on said second contact.

15. The battery of claim 14 wherein said insulating layer comprises plastic.

16. The battery of claim 1, wherein said cell structure comprises:

an anode,

an electrolyte; and

a cathode.

17. The battery of claim 16 wherein said cathode is not annealed.

18. The battery of claim 16 wherein said cathode is annealed via rapid thermal anneal.

19. The battery of claim 1 further comprising a barrier layer between said cell structure and said second contact.

20. The battery of claim 1 further comprising a contact area in said first electrical contact.

21. The battery of claim 20 wherein said contact area in said first electrical contact further comprises a lead extending from said first electrical contact.

22. The battery of claim 1 further comprising a contact area in said second electrical contact.

23. The battery of claim 22 wherein said contact area in said second electrical contact further comprises a lead extending from said second electrical contact.

24. The battery of claim 1 further comprising at least one opening in first contact.

25. The battery of claim 1 wherein said first contact comprises a metal foil.

26. The battery of claim 1 wherein said second contact comprises a metal foil.

27. The battery of claim 1 further comprising a plurality of openings in said first contact.

28. The battery of claim 1 further comprising a second cell structure.

29. The battery of claim 28 wherein said metal foil also encapsulates said second cell structure with at least one notch and a portion of said first contact extends over said notch providing an electrical contact tab on said first contact over the notched portion of said cell structure.

30. The battery of claim 1 wherein the first contact acts as a cathode element of said cell structure.

31. The battery of claim 1 wherein the first contact acts as an anode element of said cell structure.

32. The battery of claim 1 further comprising a plurality of cell structures with at least one notch in each cell structure, and stacked one upon another with at least one metal foil encapsulating each cell structure.

33. The battery of claim 32 further comprising a plurality of cell structures.

34. The battery of claim 1 wherein said first contact lays over said electrochemical device.

35. The battery of claim 1 wherein said first contact comprises stainless steel.

36. The battery of claim 1 wherein said portions of said first contact are coated with an insulating material.

37. The battery of claim 1 wherein said first contact is less than approximately 100 microns thick.

38. The battery of claim 1 wherein said first contact is less than approximately 50 microns thick.

39. The battery of claim 1 wherein said first contact is less than approximately 25 microns thick.

40. A battery comprising:

a first electrical contact;

a bonding layer comprising means for conducting between said bonding layer and first electrical contact.

at least one cell structure; and

a second electrical contact,

wherein said bonding layer and said at least one cell structure are sandwiched between said first and second contact layers.

41. The battery of claim 40, wherein said conducting means is selectively conductive.

42. The battery of claim 40, wherein said cell structure is in selective electrical contact with said first electrical contact via said conducting means.

43. The battery of claim 40, wherein said first electrical contact further comprises an encapsulate metal.

44. The battery of claim 40, wherein said second electrical contact further comprises a substrate.

45. The battery of claim 40, wherein said bonding layer comprises a material selected from the group comprising an adhesive material, an insulating material, plastic, glass, KEVLAR®

, reinforcement materials, and fiberglass.

46. The battery of claim 40, wherein said conductive means is selected from the group consisting of a tab, a wire, multiple wires, a wire mesh, perforated metal, a metal coating applied to the adhesive layer, and a disk.

47. The battery of claim 40, wherein said conductive means is woven within said bonding layer.

48. The battery of claim 47, wherein said bonding layer comprises a slit within which said embedded conductor is woven.

49. The battery of claim 40, wherein said second contact comprises a material selected from the group consisting of gold, platinum, stainless steel, titanium, zirconium, cobalt, aluminum, indium, nickel, copper, silver, carbon, bronze, brass, beryllium, and oxides, nitrides, and alloys thereof.

50. The battery of claim 40, wherein said conductive means comprises a material selected from the group consisting of gold, platinum, stainless steel, titanium, zirconium, cobalt, aluminum, indium, nickel, copper, silver, carbon, bronze, brass, beryllium, and oxides, nitrides, and alloys thereof.

51. The battery of claim 40 further comprising an insulating layer on said first contact.

52. The battery of claim 51 wherein said insulating layer comprises plastic.

53. The battery of claim 40 further comprising an insulating layer on said second contact.

54. The battery of claim 53 wherein said insulating layer comprises plastic.

55. The battery of claim 40, wherein said cell structure comprises:

an anode,

an electrolyte; and

a cathode.

56. The battery of claim 55 wherein said cathode is not annealed.

57. The battery of claim 55 wherein said cathode is annealed via rapid thermal anneal.

58. The battery of claim 40 further comprising a barrier layer between said cell structure and said second contact.

59. The battery of claim 40 further comprising a barrier layer between said cell structure and said second contact.

60. The battery of claim 40 further comprising a contact area in said first electrical contact.

61. The battery of claim 60 wherein said contact area in said first electrical contact further comprises a lead extending from said first electrical contact.

62. The battery of claim 40 further comprising a contact area in said second electrical contact.

63. The battery of claim 62 wherein said contact area in said second electrical contact further comprises a lead extending from said second electrical contact.

64. The battery of claim 40 further comprising at least one opening in first contact.

65. The battery of claim 40 wherein said first contact comprises a metal foil.

66. The battery of claim 40 wherein said second contact comprises a metal foil.

67. The battery of claim 40 further comprising a plurality of openings in said first contact.

68. The battery of claim 40 further comprising a second cell structure.

69. The battery of claim 68 wherein said metal foil also encapsulates said second cell structure with at least one notch and a portion of said first contact extends over said notch providing an electrical contact tab on said first contact over the notched portion of said cell structure.

70. The battery of claim 69 wherein said contact tab is a lead extending from said battery.

71. The battery of claim 40 wherein the first contact acts as a cathode element of said cell structure.

72. The battery of claim 40 wherein the first contact acts as an anode element of said cell structure.

73. The battery of claim 40 further comprising a plurality of cell structures with at least one notch in each cell structure, and stacked one upon another with at least one metal foil encapsulating each cell structure.

74. The battery of claim 73 further comprising a plurality of cell structures.

75. The battery of claim 40 wherein said first contact lays over said electrochemical device.

76. The battery of claim 40 wherein said first contact comprises stainless steel.

77. The battery of claim 40 wherein said portions of said first contact are coated with an insulating material.

78. The battery of claim 40 wherein said first contact is less than approximately 100 microns thick.

79. The battery of claim 40 wherein said first contact is less than approximately 50 microns thick.

80. The battery of claim 40 wherein said first contact is less than approximately 25 microns thick.

81. A device comprising:

an electrochemical device with at least one notch; and

a metal foil;

wherein said metal foil encapsulates said electrochemical device and a portion of said metal foil extends over said notch providing an electrical contact tab on said metal foil over the notched portion of said electrochemical device.

82. The device of claim 81 further comprising a hole in said contact area.

83. The device of claim 81 further comprising at least one opening in said metal foil.

84. The device of claim 81 further comprising a plurality of openings in said metal foil.

85. The device of claim 81 wherein said contact tab is a lead extending from said electrochemical device.

86. The device of claim 81 further comprising a second electrochemical device.

87. The device of claim 86 wherein said metal foil also encapsulates said second electrochemical device with at least one notch and a portion of said metal foil extends over said notch providing an electrical contact tab on said metal foil over the notched portion of said electrochemical device.

88. The device of claim 87 wherein said contact tab is a lead extending from said metal foil.

89. The device of claim 81 wherein the metal foil acts as a cathode element of said electrochemical device.

90. The device of claim 81 wherein the metal foil acts as an anode element of said electrochemical device.

91. The device of claim 81 further comprising a plurality of electrochemical devices with at least one notch in each electrochemical device stacked one upon another with at least one metal foil encapsulating each electrochemical device.

92. The device of claim 91 further comprising a plurality of cell structures.

93. The device of claim 81 wherein said electrochemical device comprises a substrate and said metal foil is conductively attached to said substrate.

94. The device of claim 81 wherein said metal foil lays over said electrochemical device.

95. The device of claim 81 wherein said metal foil comprises stainless steel.

96. The device of claim 81 wherein said portions of said metal foil are coated with an insulating material.

97. The device of claim 81 wherein said metal foil is less than approximately 100 microns thick.

98. The device of claim 81 wherein said metal foil is less than approximately 50 microns thick.

99. The device of claim 81 wherein said metal foil is less than approximately 25 microns thick.

100. The device of claim 81 wherein said cathode is not annealed.

101. The device of claim 81 wherein said cathode is annealed via rapid thermal anneal.

102. A method of manufacturing a thin film battery comprising:

creating a selectively conductive bonding layer;

coupling said bonding layer with a first contact layer;

coupling a first side of a cell structure with a second contact layer; and

coupling a second side of said cell structure with said bonding layer.

103. The method of claim 102 further comprising creating said cell structure comprising creating a cell structure with an anode, cathode, and electrolyte layers.

104. The method of claim 102 wherein said creating a selectively conductive bonding layer further comprises embedding a conductor within said bonding layer.

105. The method of claim 102 wherein said conductor comprises a material selected from the group consisting of a tab, a wire, multiple wires, a wire mesh, perforated metal, a metal coating applied to the adhesive layer, a disk, and combinations thereof.

106. The method of claim 102 wherein creating a selectively conductive bonding layer comprising weaving at least one conductive wire through said bonding layer wherein selective portions of said conductive wire are exposed.

107. The method of claim 102 wherein creating a selectively conductive bonding layer comprises embedding said conductor by heating the bonding layer and compressing the conductor within said bonding layer.

108. The method of claim 102 further comprising insulating said battery with an insulating material.

109. A method of manufacturing an electrochemical device comprising:

providing an electrochemical device comprising;

providing a substrate; and

providing a notch in said electrochemical device; and

encapsulating said substrate with a metal foil, wherein said metal foil extends over the area notched in said step providing a notch and is conductively bonded to said substrate.

110. The method of claim 109 further comprising fabricating a cathode on said substrate and utilizing rapid thermal anneal.

111. The method of claim 109 further comprising the step of providing a cathode.

112. The method of claim 109 further comprising the step of providing an anode.

113. The method of claim 109 further comprising the step of providing a current collector.

114. The method of claim 109 further comprising the step of providing an electrolyte.

115. The method of claim 109 further comprising the step of providing an insulating material on said metal foil.

116. The method of claim 109 further comprising the step of providing a second electrochemical device wherein said second electrochemical device is encapsulated by said metal foil.

117. The method of claim 109 further comprising the step of providing openings in said metal foil.

118. The method of claim 109 further comprising the step of providing a barrier layer.

119. The method of claim 109 further comprising forming a lead from said metal foil.

120. A method of manufacturing a thin film battery comprising:

creating a selectively conductive bonding layer;

coupling said bonding layer with a first contact layer;

coupling a first side of a cell structure with a second contact layer; and

coupling a second side of said cell structure with said bonding layer.

121. The method of claim 120 further comprising creating said cell structure comprising creating a cell structure with an anode, cathode, and electrolyte layers.

122. The method of claim 120 wherein said creating a selectively conductive bonding layer further comprises embedding a conductor within said bonding layer.

123. The method of claim 120 wherein said conductor comprises a material selected from the group consisting of a tab, a wire, multiple wires, a wire mesh, perforated metal, a metal coating applied to the adhesive layer, a disk, and combinations thereof.

124. The method of claim 120 wherein creating a selectively conductive bonding layer comprising weaving at least one conductive wire through said bonding layer wherein selective portions of said conductive wire are exposed.

125. The method of claim 120 wherein creating a selectively conductive bonding layer comprises embedding said conductor by heating the bonding layer and compressing the conductor within said bonding layer.

126. The method of claim 120 further comprising insulating said battery with an insulating material.

127. The method of claim 120 further comprising annealing via rapid thermal anneal.

128. The method of claim 120 further comprising forming a lead from said first side of said cell structure.

129. The method of claim 120 further comprising forming a lead from said second side of said cell structure.