Method of producing a thin film battery having a protective packaging

• US 6,387,563 B1
• Filed: 03/28/2000
• Issued: 05/14/2002
• Est. Priority Date: 03/28/2000
• Status: Expired due to Term

• Current Assignee: Johnson Ip Holding Llc
• Original Assignee: Johnson Researach and Development Company Incorporated
• Inventors: Bates, John
• Primary Examiner(s): Chaney, Carol
• Assistant Examiner(s): Dove, Tracy
• Application Number:
  US09/536,535
• Time in Patent Office: 777 Days
• Field of Search: 296/232, 296/235, 296/234, 429/127, 429/162, 429/124
• US Class Current: 429/124
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0564 the electrolyte being constituted of organic materials only
• 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 50/117 Inorganic material
• CPC Class Codes: H01M 50/121 Organic material
• 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 29/4911 including sealing
• CPC Class Codes: Y10T 29/49114 including adhesively bonding
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

A method of providing a packaging system for a thin film battery (20) is now provided wherein the battery cell is treated with an epoxy (41) prior to the placement of an overlying glass layer (42). The positioning of the glass layer causes the migration or spreading of the epoxy layer across the battery cell.

Claims

1. A method of sealing a thin film battery cell comprising the steps of:

(a) positioning a quantity of epoxy upon the battery cell;

(b) positioning a layer of air impermeable material upon the quantity of epoxy so as to cause the epoxy to spread across the battery cell and thereby force gases to be expelled from between the battery cell and the overlying air impermeable material.

2. The method of claim 1 wherein the air impermeable material is a ceramic material.

3. The method of claim 2 wherein the ceramic material is an ultraviolet light transmitting glass and wherein the epoxy is an ultraviolet light curable epoxy layer.

4. The method of claim 3 further comprising the step of transmitting ultraviolet light upon the glass so as to be transmitted through the glass to the underlying epoxy layer.

5. A sealed thin film battery cell produced in accordance with the method of claim 1.

6. A sealed thin film battery cell produced in accordance with the method of claim 4.

7. A method of sealing a thin film battery cell comprising the steps of:

(a) positioning a quantity of epoxy upon the battery cell;

(b) forcing a layer of air impermeable material upon the quantity of epoxy so as to cause the epoxy to spread between the battery cell and the air impermeable material so as to substantially protect a surface area of the battery cell with the overlying air impermeable material.

8. The method of claim 7 wherein the air impermeable material is a ceramic material.

9. The method of claim 8 wherein the ceramic material is an ultraviolet light transmitting glass and wherein the epoxy is an ultraviolet light curable epoxy layer.

10. The method of claim 9 further comprising the step of transmitting ultraviolet light upon the glass so as to be transmitted through the glass to the underlying epoxy.

11. A sealed thin film battery cell produced in accordance with the method of claim 7.

12. A sealed thin film battery cell produced in accordance with the method of claim 10.

13. A thin film battery including components which are capable of reacting upon exposure to air and water vapor, the improvement comprising;

a thin protective layer overlying and coating at least a portion of the battery components so that the protective layer provides a thin film barrier against the penetration of air and water vapor; and

an underlying coating of epoxy between the battery components and the protective layer.

14. The thin film battery of claim 13 wherein the protective layer is a ceramic layer.

15. The thin film battery of claim 14 wherein the protective layer is an ultraviolet light transmitting glass and wherein the epoxy layer is an ultraviolet light curable epoxy layer.

16. A thin film battery including components which are capable of reacting upon exposure to air, the improvement comprising;

a protective sheath overlying and coating the battery components so that the sheath provides a thin film barrier against the penetration of air, wherein the protective sheath includes a layer of ultraviolet light transmitting ceramic material and a layer of ultraviolet light curable epoxy positioned between the battery components and the ceramic material.