Flexible thin printed battery and device and method of manufacturing same

• US 7,727,290 B2
• Filed: 10/21/2009
• Issued: 06/01/2010
• Est. Priority Date: 02/12/2002
• Status: Expired due to Term

• Current Assignee: Energizer Brands, LLC (Energizer Holdings, Inc.)
• Original Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Inventors: Zhang, Jing, Schubert, Mark A., Zheng, Guanghong
• Primary Examiner(s): HODGE, ROBERT W
• Application Number:
  US12/603,114
• Publication Number:
  US 20100040941A1
• Time in Patent Office: 223 Days
• Field of Search: None
• US Class Current: 29/623.5
• 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 method for making an electrochemical battery cell comprising a printed negative electrode, the method comprising the steps:

a. preparing a zinc containing ink by mixing an aqueous solvent, a zinc powder, a binder soluble in the solvent, and a zinc compound soluble in the solvent and comprising a member selected from the group consisting of zinc chloride and zinc acetate, without substantially oxidizing the zinc powder;

b. printing the zinc containing ink onto a substrate to form a negative electrode;

c. preparing a positive electrode;

d. preparing an aqueous electrolyte;

e. combining the negative electrode, positive electrode and electrolyte in a container; and

f. sealing the container to form a sealed electrochemical battery cell.

2. The method according to claim 1, wherein the electrolyte is an alkaline electrolyte.

3. The method according to claim 2, wherein the zinc compound comprises zinc chloride.

4. The method according to claim 2, wherein the binder comprises polyethylene oxide.

5. The method according to claim 1, wherein the electrolyte is an acidic electrolyte.

6. The method according to claim 5, wherein the zinc compound comprises zinc acetate.

7. The method according to claim 5, wherein the binder comprises polyvinylpyrrolidone.

8. The method according to claim 7, wherein the aqueous solvent comprises N-methylpyrrolidone.

9. The method according to claim 1, wherein the cell comprises a separator comprising a paper.

10. The method according to claim 1, wherein the cell comprises a separator comprising a gelled electrolyte.

11. The method according to claim 10, wherein the electrolyte is an acidic electrolyte comprising a gelling agent and the gelling agent comprises a member selected from the group consisting of nonionic and anionic derivatives and natural guar gum, a polyethylene glycol based polymer, polyethylene oxide, and fumed silica.

12. The method according to claim 11, wherein the separator is printed onto at least one of the negative and positive electrodes and comprises a polyethylene glycol based polymer, and fumed silica.

13. The method according to claim 1, wherein the substrate is flexible and electrically non-conductive.

14. The method according to claim 1, wherein the negative electrode is printed directly onto the substrate with no intervening current collector between the substrate and the ink.

15. The method according to claim 14, wherein the electrodes and the separator are flexible and the container comprises a flexible pouch.