Polymer-lithium batteries and improved methods for manufacturing batteries
First Claim
Patent Images
1. A method for manufacturing thin batteries, comprising:
- forming a cathode layer by depositing a cathode material onto a cathode substrate in a pattern to form cathodes;
separating the cathodes with an insulating cathode mask;
forming a separator/electrolyte layer of a solid electrolyte material in contact with the cathodes;
forming an anode layer by depositing an anode material as a patterned solder on an anode substrate to form anodes for contact with the separator/electrolytic layer;
separating the anodes with an insulated anode mask;
combining the separate layers together to form a laminated array structure containing multiple battery cells; and
singulating individual battery cells from the laminated array structure.
6 Assignments
0 Petitions
Accused Products
Abstract
Improved polymer batteries and improved methods of manufacturing such polymer batteries are provided. One improved method of manufacture involves the formation of a laminated array structure that includes a number of individual battery cells. After formation of the laminated array the individual batteries are singulated from the array by cutting, shearing or stamping. Other manufacturing improvements include the use of a printing process (e.g. stenciling) to form the cathodes, the use of permanent mask layers to contain and insulate the cathodes and anodes, and the use of a molten lithium deposition process for forming the anodes.
-
Citations
25 Claims
-
1. A method for manufacturing thin batteries, comprising:
-
forming a cathode layer by depositing a cathode material onto a cathode substrate in a pattern to form cathodes; separating the cathodes with an insulating cathode mask; forming a separator/electrolyte layer of a solid electrolyte material in contact with the cathodes; forming an anode layer by depositing an anode material as a patterned solder on an anode substrate to form anodes for contact with the separator/electrolytic layer; separating the anodes with an insulated anode mask; combining the separate layers together to form a laminated array structure containing multiple battery cells; and singulating individual battery cells from the laminated array structure. - View Dependent Claims (2, 3, 4, 5, 7, 8)
-
-
6. The method as claimed in claim i and wherein the cathode layer is formed by depositing a cathode material on the cathode substrate using a stencil to pattern the cathode material.
-
9. A method of manufacturing thin polymer batteries by forming a laminated array containing multiple battery cells by the steps comprising;
-
forming a cathode substrate layer of a conductive material; forming cathodes for the battery cells by depositing a cathode material in a discrete pattern on the cathode substrate layer and separating the cathodes with a cathode mask; placing a separator/insulator layer in contact with the cathodes; forming an anode substrate layer of a conductive material; forming anodes for the battery cells by depositing a molten anode material in a discreet pattern on the anode substrate layer and separating the anodes with an anode mask; placing the anodes in contact with the separator/insulator layer; and singulating the individual battery cells from the laminated array. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
-
-
17. A method of forming a thin battery comprising the steps of:
-
providing a cathode substrate layer; depositing a cathode material on the substrate layer using a first stencil formed with a first opening and printing the cathode material through the first opening onto the substrate layer to form a cathode; depositing an electrolytic material on the cathode using a second stencil formed with a second opening and printing the electrolytic material through the second opening onto the cathode; and forming an anode on the electrolytic material. - View Dependent Claims (18)
-
-
19. A thin battery comprising:
-
a cathode substrate formed of a conductive material; a cathode deposited in a discrete pattern on the cathode substrate by depositing a cathode material on the cathode substrate using a printing process; a cathode mask formed on the cathode substrate for separating and insulating the cathode said cathode mask including studs to prevent compression and shorting of the cathode; a separator/electrolyte layer in contact with the cathode; an anode deposited in a discrete pattern on a conductive anode substrate in contact with the separator/electrolyte layer and formed by depositing a molten anode material onto the anode substrate; and an anode mask formed on the anode substrate for separating and insulating the anode. - View Dependent Claims (20, 21, 22, 23, 24, 25)
-
Specification