Flexible thin printed battery and device and method of manufacturing same

• US 7,348,096 B2
• Filed: 12/17/2002
• Issued: 03/25/2008
• Est. Priority Date: 02/12/2002
• Status: Active Grant

• Current Assignee: Energizer Brands, LLC (Energizer Holdings, Inc.)
• Original Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Inventors: Langan, Richard A., Zhang, Jing, Schubert, Mark A., Tucholski, Gary R., Bailey, John C., Zheng, Guanghong, Webber, Andrew, Hilmi, Abdelkader, Feddrix, Frank H., Tudron, Frank B.
• Primary Examiner(s): Crepeau; Jonathan
• Assistant Examiner(s): HODGE, ROBERT W
• Application Number:
  US10/321,182
• Publication Number:
  US 20030165744A1
• Time in Patent Office: 1,925 Days
• Field of Search: None
• US Class Current: 429/127
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2004/028 Positive electrodes
• CPC Class Codes: H01M 2300/0002 Aqueous electrolytes
• CPC Class Codes: H01M 2300/0014 Alkaline electrolytes
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0414 by screen printing
• CPC Class Codes: H01M 4/06 Electrodes for primary cells
• CPC Class Codes: H01M 4/08 Processes of manufacture
• CPC Class Codes: H01M 4/244 Zinc electrodes
• CPC Class Codes: H01M 4/26 Processes of manufacture
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/62 Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/623 fluorinated polymers
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: H01M 4/663 containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/42 Acrylic resins
• CPC Class Codes: H01M 50/463 : Separators, membranes or diaphragms characterised by their shape
• CPC Class Codes: H01M 50/497 : Ionic conductivity
• CPC Class Codes: H01M 6/045 : characterised by aqueous electrolyte
• CPC Class Codes: H01M 6/12 : with flat electrodes
• CPC Class Codes: H01M 6/22 : Immobilising of electrolyte
• 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 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating

Abstract

A flat, flexible electrochemical cell is provided. The within invention describes various aspects of the flat, flexible electrochemical cell. A printed anode is provided that obviates the need for a discrete anode current collector, thereby reducing the size of the battery. An advantageous electrolyte is provided that enables the use of a metallic cathode current collector, thereby improving the performance of the battery. Printable gelled electrolytes and separators are provided, enabling the construction of both co-facial and co-planar batteries. Cell contacts are provided that reduce the potential for electrolyte creepage in the flat, flexible electrochemical cells of the within invention.

Claims

1. A flat flexible battery comprising an electrode, at least one electrode internal current collector having first and second ends and at least one electrode external terminal having first and second ends, and a flexible nonconductive packaging material, said packaging material sealed together at at least one seal junction to form a seal area and a sealed housing surrounding said electrode, wherein said internal current collector and said external terminal are discrete structures, and wherein said internal current collector first end contacts said electrode, said internal current collector second end is positioned within said seal junction, said external terminal first end is positioned within said seal junction and said external terminal second end is positioned external said seal junction and external said housing wherein said internal current collector and said external terminal are not in physical contact within said seal junction.

2. The battery of claim 1, further comprising an electrically conductive medium disposed between the second end of the internal current collector and the first end of the external terminal.

3. The battery as defined in claim 2, wherein the electrically conductive medium comprises electrically conductive adhesive.

4. The battery as defined in claim 2, wherein the electrically conductive medium comprises epoxy.