Method of making a thin film battery

• US 6,379,835 B1
• Filed: 08/01/2000
• Issued: 04/30/2002
• Est. Priority Date: 01/12/1999
• Status: Expired due to Term

• Current Assignee: Morgan Adhesives Company (Amcor Plc)
• Original Assignee: Morgan Adhesives Company (Amcor Plc)
• Inventors: Miller, James A., Simmons, George R., Mlnarik, Christopher F., Kucherovsky, Joseph S.
• Primary Examiner(s): Walker, W. L.
• Assistant Examiner(s): SORKIN, DAVID L
• Application Number:
  US09/630,214
• Time in Patent Office: 637 Days
• Field of Search: 429/110, 429/116, 429/117, 429/118, 429/119, 429/162, 427/58, 427/96
• US Class Current: 429/118
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 2300/0002 Aqueous electrolytes
• CPC Class Codes: H01M 2300/0017 Non-aqueous electrolytes
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/30 Deferred-action cells
• CPC Class Codes: H01M 6/38 by mechanical means
• 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

Abstract

A flexible thin film battery including a film layer and a porous cathode deposited on a portion of a film and a porous anode deposited on a portion of the film, with an electrolyte and separator layer positioned between the porous anode and the porous cathode. The electrolyte is preferably dried so the battery is activated when liquid contacts the electrolyte and separator layer. In a preferred embodiment, water swellable particles are included in the cell. The film layers are least partially sealed around the edges, confining the anode, cathode, and electrolyte and separator layer. The method of producing such a battery preferably includes printing various inks in a pattern on a polymeric film.

Claims

1. A method of producing a thin film battery adapted to activate when liquid contacts an electrolyte and separator layer, the method comprising the steps of:

providing a polymeric film;

printing on the polymeric film in a pattern solvent inks that include a water swellable polymer to form electrodes;

depositing an electrolyte and separator layer in physical and ionic contact with the electrodes;

providing a means for passage of liquid to the electrolyte and separator layer; and

sealing the polymeric film on at least a section of its edges thereby confining the electrodes and electrolyte and separator layer.

2. The method of producing a thin film battery of claim 1 wherein the step of depositing an electrolyte and separator layer includes printing a coating of zinc chloride ink with micro-spheres and drying the zinc chloride ink.

3. The method of producing a thin film battery of claim 1 wherein the step of depositing an electrolyte and separator layer includes inserting a porous membrane with a non-liquid electrolyte embedded in the membrane.

4. The method of producing a thin film battery of claim 1 wherein the step of depositing an electrolyte and separator layer includes printing a zinc chloride, ammonium chloride, polyvinyl alcohol ink and drying the ink.

5. The method of producing a thin film battery of claim 1 including the additional step of printing a current collector on a portion of the polymeric film.

6. The method of producing a thin film battery of claim 1 wherein solvent inks are non-aqueous.

7. The method of producing a thin film battery of claim 1 including the additional step of adding a second film whereby the polymeric film is sealed on at least a section of its edges to the second film.

8. The method of producing a thin film battery of claim 7 wherein the second film is permeable to gas.

9. The method of producing a thin film battery of claim 7 wherein the second film is water permeable, thereby providing means for passage of liquid to the electrolyte and separator layer.

10. The method of producing a thin film battery of claim 7 wherein the means for passage of liquid to the electrolyte and separator layer is forming an aperture in the second film.

11. The method of producing a thin film battery of claim 1 wherein the step of depositing an electrolyte and separator layer in physical and ionic contact with the electrodes includes printing and drying an electrolyte composition on a separator.

12. The method of producing a thin film battery of claim 1 including the additional step of preparing solvent inks that include electrode powders.

13. The method of producing a thin film battery of claim 1 wherein the step of providing a means for passage of liquid is forming an aperture in the polymeric film.

14. The method of producing a thin film battery of claim 1 wherein the step of providing a means for passage of liquid includes leaving gaps in the seal around the edges of the polymeric film.