Battery constructions and method for forming such battery constructions

• US 5,906,661 A
• Filed: 02/24/1998
• Issued: 05/25/1999
• Est. Priority Date: 06/02/1993
• Status: Expired due to Term

• Current Assignee: Round Rock Research LLC
• Original Assignee: Micron Communications, Inc. (Micron Technology, Inc.)
• Inventors: Lake, Rickie C.
• Primary Examiner(s): Maples, John S.
• Application Number:
  US09/028,694
• Time in Patent Office: 455 Days
• Field of Search: 429/124, 429/162, 29/623.5, 29/623.1
• US Class Current: 29/623.5
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/08 Processes of manufacture
• CPC Class Codes: H01M 4/381 Alkaline or alkaline earth metals elements H01M4/40 takes precedence
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/66 Selection of materials
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/666 in the form of mixed materials H01M4/668 takes precedence
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 4/668 Composites of electroconductive material and synthetic resins
• CPC Class Codes: H01M 4/75 Wires, rods or strips
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/548 on opposite sides of the cell
• CPC Class Codes: H01M 50/555 Window-shaped terminals
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: H01M 6/181 with polymeric electrolytes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• 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

In one aspect, a method of making a battery includes fusing an alkali metal onto a patterned conductive layer. In another aspect, a method of forming a battery includes: a) providing a cathode base which comprises: a first nonconductive surface; a first conductive layer superjacent the first nonconductive surface; the first conductive layer comprising a first area; and a cathode layer superjacent the first conductive layer leaving at least a portion of the first area exposed; b) providing an anode base which comprises: a second nonconductive surface; a second conductive layer superjacent the first nonconductive surface, the second conductive layer comprising a second area; and an anode layer superjacent the second conductive layer leaving at least a portion of the second area exposed, the anode layer comprising an alkali metal; and c) aligning and coupling the anode layer of the anode base with the cathode layer of the cathode base, wherein the aligning and coupling leaves at least a portion of the first area and at least a portion of the second area exposed for electrical connection. The invention also encompasses batteries formed by such methods.

Claims

1. A method of forming a battery, comprising:

providing a cathode base having a cathode layer over and in electrical connection with a first conductive substrate, the cathode layer covering only a portion of the first conductive substrate to leave another portion of the first conductive substrate uncovered;

providing an anode base having an anode layer over and in electrical connection with a second conductive substrate, the anode layer covering only a portion of the second conductive substrate to leave another portion of the second conductive substrate uncovered; and

incorporating the anode base and the cathode base into a battery, at least a part of the uncovered portion of the first conductive substrate being exposed within said battery for electrical connection thereto, and at least a part of the uncovered portion of the second conductive substrate being exposed within said battery for electrical connection thereto.

2. A method of forming a battery, comprising:

providing a cathode base, the cathode base comprising;

a first nonconductive surface;

a first conductive layer over the first nonconductive surface; and

a cathode layer over the first conductive layer, the cathode layer covering only a portion of the first conductive layer to leave another portion of the first conductive layer uncovered;

providing an anode base, the anode base comprising;

a second nonconductive surface;

a second conductive layer over the second nonconductive surface;

an anode layer over the second conductive layer, the anode layer covering only a portion of the second conductive layer to leave another portion of the second conductive layer uncovered; and

incorporating the anode base and the cathode base into a battery, at least a part of the uncovered portion of the first conductive layer being exposed within said battery for electrical connection thereto, and at least a part of the uncovered portion of the second conductive layer being exposed within said battery for electrical connection thereto.

3. A method of forming a battery, comprising:

providing a cathode base, the cathode base comprising;

a first nonconductive surface;

a first conductive layer over the first nonconductive surface, the first conductive layer comprising a first area; and

a cathode layer over the first conductive layer leaving at least a portion of the first area exposed;

providing an anode base, the anode base comprising;

a second nonconductive surface;

a second conductive layer over the second nonconductive surface, the second conductive layer comprising a second area;

an anode layer over the second conductive layer leaving at least a portion of the second area exposed, the anode layer comprising a metal; and

incorporating the anode base and the cathode base into a battery, at least a portion of the first area and at least a portion of the second area being exposed within said battery for electrical connection thereto.

4. The method of claim 3 wherein the metal comprised by the anode layer is an alkali metal.

5. The method of claim 3 further comprising providing an electrolyte layer between the anode layer and the cathode layer.

6. The method of claim 5 wherein the electrolyte layer comprises an electrolyte film.

7. The method of claim 3 further comprising a step of printing the first conductive layer onto the first nonconductive surface.

8. The method of claim 3 further comprising a step of printing the cathode layer onto the first conductive layer.

9. The method of claim 3 further comprising a step of applying an electrolyte layer over one or both of the cathode layer and the anode layer prior to the step of incorporating the anode layer and the cathode layer into the battery.

10. The method of claim 3 further comprising:

applying an electrolyte layer over one or both of the cathode layer and the anode layer prior to the step of incorporating the anode layer and the cathode layer into a battery, wherein one or more of the first conductive layer, cathode layer, second conductive layer and electrolyte layer is applied as a liquid; and

curing the one or more of the first conductive layer, cathode layer, second conductive layer and electrolyte layer by exposing the one or more layers to energy in at least one form of the forms selected from the group consisting of heat, infrared light, ultraviolet light, and electron beam radiation.

11. The method of claim 3 further comprising a step of printing the second conductive layer onto the second nonconductive surface.

12. The method of claim 3 further comprising a step of fusing the anode layer onto the second conductive layer.