Flexible thin printed battery and device and method of manufacturing same
First Claim
1. A battery including an electrochemical cell, said electrochemical cell comprising:
- a substrate having an inner surface and a plurality of laminated layers, wherein said plurality of laminated layers includes a high-moisture barrier layer;
a first printed ink electrochemical layer covering some portion of said inner surface;
a second printed ink electrochemical layer covering another portion of said inner surface;
an electrolyte layer substantially covering and in contact with both said first electrochemical layer and said second electrochemical layer;
a covering layer covering said electrolyte layer and bound to said substrate to form a pouch for sealing said electrolyte layer in an interior of said cell, wherein the covering layer is sealed to the substrate at at least one seal junction to form a seal area bounded by inner and outer boundaries;
at least one electrode inner current collector having first and second opposing ends, wherein the first end of the current collector contacts one of the first and second electrochemical layers and the second end of the current collector is positioned within the seal junction; and
at least one electrode external terminal having first and second ends, wherein the first end of the external terminal is positioned within the seal junction and the second end of the external terminal is positioned external the seal junction, wherein the internal current collector and the external terminal are discrete structures, and wherein the second end of the current collector and the first end of the external terminal terminate within the seal junction at a location distanced from the inner and outer boundaries of the seal junction.
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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.
38 Citations
51 Claims
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1. A battery including an electrochemical cell, said electrochemical cell comprising:
- a substrate having an inner surface and a plurality of laminated layers, wherein said plurality of laminated layers includes a high-moisture barrier layer;
a first printed ink electrochemical layer covering some portion of said inner surface;
a second printed ink electrochemical layer covering another portion of said inner surface;
an electrolyte layer substantially covering and in contact with both said first electrochemical layer and said second electrochemical layer;
a covering layer covering said electrolyte layer and bound to said substrate to form a pouch for sealing said electrolyte layer in an interior of said cell, wherein the covering layer is sealed to the substrate at at least one seal junction to form a seal area bounded by inner and outer boundaries;
at least one electrode inner current collector having first and second opposing ends, wherein the first end of the current collector contacts one of the first and second electrochemical layers and the second end of the current collector is positioned within the seal junction; and
at least one electrode external terminal having first and second ends, wherein the first end of the external terminal is positioned within the seal junction and the second end of the external terminal is positioned external the seal junction, wherein the internal current collector and the external terminal are discrete structures, and wherein the second end of the current collector and the first end of the external terminal terminate within the seal junction at a location distanced from the inner and outer boundaries of the seal junction. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50)
- a substrate having an inner surface and a plurality of laminated layers, wherein said plurality of laminated layers includes a high-moisture barrier layer;
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51. A flat flexible battery comprising a substrate, first and second electrodes separately layered on the substrate, at least one electrode internal current collector having first and second opposing ends and at least one electrode external terminal having first and second ends, an electrolyte layer covering the first and second electrodes and a flexible nonconductive packaging material, said packaging material sealed together at at least one seal junction to form a seal area bounded by inner and outer boundaries and a sealed housing surrounding said electrodes, wherein said internal current collector and said external terminal are discrete structures, and wherein said internal current collector first end contacts one of said electrodes, 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 the second end of the at least one electrode internal current collector is positioned within said seal junction at a location distanced from the inner and outer boundaries of the seal junction, and wherein the external terminal first end is positioned within the seal junction at a location distanced from the inner and outer boundaries of the seal junction.
Specification