Thin film battery with protective packaging

• US 8,168,322 B2
• Filed: 05/19/2010
• Issued: 05/01/2012
• Est. Priority Date: 03/25/2005
• Status: Active Grant

• Current Assignee: KLA Corporation
• Original Assignee: Front Edge Technology, Inc
• Inventors: Krasnov, Victor, Nieh, Kai-Wei
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): Lewis, Ben
• Application Number:
  US12/783,520
• Publication Number:
  US 20100227214A1
• Time in Patent Office: 713 Days
• Field of Search: 429/175, 429/135, 429/148, 429/162, 429/169, 429/177, 429/186, 429/246, 429/247
• US Class Current: 429/175
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0562 Solid materials
• 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 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 50/117 Inorganic material
• CPC Class Codes: H01M 50/141 for protecting against humidity
• CPC Class Codes: H01M 50/147 Lids or covers
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/193 Organic material
• CPC Class Codes: H01M 50/198 characterised by physical properties, e.g. adhesiveness or hardness
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• 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 battery comprises a substrate comprising a first surface comprising a first battery cell having a first non-contact surface, a pliable dielectric abutting the first non-contact surface, the pliable dielectric comprising a peripheral edge, and a first cap about the pliable dielectric.

Claims

1. A battery comprising:

(a) a substrate comprising a first surface comprising a first battery cell having a first non-contact surface;

(b) a pliable dielectric abutting the first non-contact surface; and

(c) a first cap about the pliable dielectric.

2. A battery according to claim 1 wherein the substrate comprises a second surface having a second battery cell with a second non-contact surface, the pliable dielectric abuts the first and second non-contact surfaces, and a second cap is about the pliable dielectric.

3. A battery according to claim 2 wherein the first and second caps each comprise a metal foil, metalized plastic film or metal casing.

4. A battery according to claim 2 wherein the first and second caps each comprise mica, quartz, ceramic casing or glass.

5. A battery according to claim 2 wherein the first and second battery cells each comprise an electrolyte between a pair of conductors, at least one of the conductors comprising the first or second non-contact surfaces, and further comprising a pair of electrical connectors that extend though the pliable dielectric, each electrical connector being connected to at least one conductor of the first or second battery cells.

6. A battery according to claim 1 comprising a plurality of side faces that are not enclosed by the first cap, and wherein the ratio of the area of any one of the first or second non-contact surfaces to the total area of the side faces is at least about 10:

1.

7. A battery according to claim 6 wherein the ratio of the area of any one of the first or second non-contact surfaces to the total area of the side faces is from about 20:

1 to about 50;

1.

8. A battery according to claim 1 wherein the pliable dielectric comprises a thickness of from about 1 μ

m to about 20 μ

m.

9. A battery according to claim 8 wherein the pliable dielectric comprises a moisture permeability of less than about 10 g·

mil/(100 in²·

day).

10. A battery according to claim 1 wherein the pliable dielectric comprises Apiezon®

, paraffin, wax, mineral oil or mixtures thereof.

11. A battery comprising:

(a) a substrate comprising a first surface comprising a first battery cell having a first non-contact surface, and a second surface having a second battery cell with a second non-contact surface,

(b) a pliable dielectric abutting the first and second non-contact surfaces; and

(c) first and second caps about the pliable dielectric.

12. A battery according to claim 11 wherein the first and second caps each comprise a metal foil, metalized plastic film or metal casing.

13. A battery according to claim 11 wherein the first and second caps each comprise a sheet of mica, quartz, ceramic casing or glass casing.

14. A battery according to claim 11 wherein the first and second battery cells each comprise an electrolyte between a pair of conductors, at least one of the conductors comprising the first or second non-contact surfaces, and further comprising a pair of electrical connectors that extend though the pliable dielectric, each electrical connector being connected to at least one conductor of the first or second battery cells.

15. A battery according to claim 11 comprising a plurality of side faces that are not enclosed by the first and second caps, and wherein the ratio of the area of any one of the first or second non-contact surfaces to the total area of the side faces is at least about 10:

1.

16. A battery according to claim 11 wherein the pliable dielectric comprises a thickness of from about 1 μ

m to about 20 μ

m, and a moisture permeability of less than about 10 g·

mil/(100 in²·

day).

17. A battery according to claim 11 wherein the pliable dielectric comprises Apiezon®

, paraffin, wax, mineral oil or mixtures thereof.

18. A battery comprising:

(a) a first substrate comprising opposing surfaces, at least one of the opposing surfaces comprising a battery cell having a non-contact surface abutting a first pliable dielectric, and a pair of first caps about the first pliable dielectric;

(b) a second substrate comprising opposing surfaces, at least one of the opposing surfaces comprising a battery cell having a non-contact surface abutting a second pliable dielectric, and a pair of second caps about the second pliable dielectric;

(c) a seal extending around the side faces of a gap between a first cap and a second cap.

19. A battery according to claim 18 wherein the pairs of first and second caps each comprise a metal foil, metalized plastic film or metal casing.

20. A battery according to claim 18 wherein the pairs of first or second caps each comprise a sheet of mica, quartz, ceramic casing or glass casing.

21. A battery according to claim 18 wherein the seal comprises at least one of:

(1) a moisture permeability of less than about 1.75 g·

mil/(100 in²·

day); and

(2) epoxy, polymerized ethylene acid copolymer, Apiezon®

, paraffin, wax, Surlyn™

or mixtures thereof.

22. A battery according to claim 18 wherein the first and second pliable dielectrics each have a thickness of from about 1 μ

m to about 20 μ

m, and a moisture permeability of less than about 10 g·

mil/(100 in²·

day).

23. A battery according to claim 18 wherein the first and second pliable dielectrics each comprise Apiezon®

, paraffin, wax, mineral oil or mixtures thereof.

24. A battery comprising:

(a) a first substrate comprising opposing surfaces having a first hole therethrough, the first hole having an edge;

(b) at least one first battery cell on an opposing surface of the first substrate, the first battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a first terminal contacting the edge of the first hole;

(c) a second substrate comprising opposing surfaces, at least one of the opposing surfaces comprising a second battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a second terminal; and

(d) an electrical conductor extending through the first hole to contact a second terminal, thereby electrically connecting a first terminal to a second terminal.

25. A battery according to claim 24 comprising a seal extending around the side faces of a gap between the first substrate and the second substrate.

26. A battery according to claim 25 wherein the seal comprises at least one of:

(1) a moisture permeability of less than about 1.75 g·

mil/(100 in²·

day);

(2) a thickness of from about 1 μ

m to about 20 μ

m; and

(3) epoxy, polymerized ethylene acid copolymer, Apiezon®

, paraffin, wax, Surlyn™

or mixtures thereof.

27. A battery comprising:

(a) a first substrate comprising opposing first and second surfaces and having a first hole extending from the first surface to the second surface, the first hole having an edge;

(b) a first battery cell on the first surface of the first substrate, the first battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a first terminal contacting an edge of the first hole;

(c) a second battery cell on the second surface of the first substrate, the second battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a second terminal contacting an edge of the first hole; and

(d) a first electrical conductor extending through the first hole to electrically connect the first terminal to the second terminal.

28. A battery according to claim 27 further comprising:

(e) a second substrate comprising opposing third and fourth surfaces and having a second hole extending from the third surface to the fourth surface, the second hole having an edge;

(f) a third battery cell on the third surface of the second substrate, the third battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a third terminal contacting an edge of the second hole;

(g) a fourth battery cell on the fourth surface of the second substrate, the fourth battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a fourth terminal contacting an edge of the second hole; and

(h) a second electrical conductor extending through the second hole to electrically connect the third terminal to the fourth terminal.

29. A battery according to claim 27 comprising at least one of:

(1) a first pliable dielectric abutting a conductor of the first battery cell; and

(2) a second pliable dielectric abutting a conductor of the second battery cell.

30. A battery according to claim 29 wherein at least one of the first and second pliable dielectrics comprises a thickness of from about 1 μ

m to about 20 μ

m.

31. A battery according to claim 27 comprising at least one of:

(1) a first cap and a first seal extending around the side faces of a gap between the first cap and the first surface of the first substrate; and

(2) a second cap and a second seal extending around the side faces of a gap between the second cap and the second surface of the first substrate.

32. A battery according to claim 31 wherein at least one of the first and secod seals comprises a thickness of from about 1 μ

m to about 20 μ

m.

33. A battery comprising:

(a) a first substrate comprising opposing surfaces, the opposing surfaces having a first hole therethrough, the first hole having an edge;

(b) at least one first battery cell on an opposing surface of the first substrate, the first battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a non-contact surface abutting a pliable dielectric and a first terminal contacting an edge of the first hole;

(c) a second substrate comprising opposing surfaces, at least one of the opposing surfaces comprising a second battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a second terminal and a non-contact surface abutting a pliable dielectric; and

(d) a first electrical conductor extending through the first hole and a pliable dielectric to contact a second terminal, thereby electrically connecting a first terminal to a second terminal.

34. A battery according to claim 33 wherein the opposing surfaces of the second substrate comprise a second hole therethrough, the second hole having an edge that contacts the second terminal.

35. A battery according to claim 34 further comprising:

(e) a third substrate comprising opposing surfaces, at least one of the opposing surfaces comprising a third battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a third terminal and a non-contact surface abutting a pliable dielectric; and

(f) a second electrical conductor extending through the second hole and a pliable dielectric to contact a third terminal, thereby electrically connecting a second terminal to a third terminal.

36. A battery according to claim 33 comprising first and second caps.

37. A battery according to claim 35 comprising first and second caps.

38. A battery comprising:

(a) a substrate comprising opposing first and second surfaces and having a hole extending from the first surface to the second surface, the hole having an edge;

(b) a first battery cell on the first surface of the substrate, the first battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a first terminal contacting an edge of the hole and a first non-contact surface abutting a pliable dielectric;

(c) a second battery cell on the second surface of the substrate, the second battery cell comprising an electrolyte between a pair of conductors, the conductors comprising a second terminal contacting an edge of the hole and a second non-contact surface abutting a pliable dielectric;

(d) an electrical conductor extending through the hole to electrically connect the first terminal to the second terminal; and

(e) first and second caps.