Thin printable electrochemical cell and methods of making the same

• US 8,268,475 B2
• Filed: 09/01/2011
• Issued: 09/18/2012
• Est. Priority Date: 03/22/2005
• Status: Active Grant

• Current Assignee: Blue Spark Innovations LLC
• Original Assignee: Blue Spark Technologies, Inc.
• Inventors: Tucholski, Gary R.
• Primary Examiner(s): Crepeau, Jonathan
• Assistant Examiner(s): DOUYETTE, KENNETH J
• Application Number:
  US13/223,845
• Publication Number:
  US 20110311857A1
• Time in Patent Office: 383 Days
• Field of Search: 429/223, 429/322, 429/245, 429/127, 429/162, 429/163, 429/185, 429/246, 429/217, 429/224
• US Class Current: 429/162
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/365 Zinc-halogen accumulators
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 12/085 Zinc-halogen cells or batteries
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• CPC Class Codes: H01M 4/42 Alloys based on zinc
• CPC Class Codes: H01M 4/50 of manganese
• 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 50/105 Pouches or flexible bags
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/126 comprising three or more layers
• CPC Class Codes: H01M 50/133 Thickness
• 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 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: H01M 6/42 : Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H01M 6/46 : of flat cells
• 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 29/49115 : including coating or impregnating

Abstract

A thin printed flexible electrochemical cell, and its method of manufacture, using a “picture frame” structure sealed, for example, with a high moisture and oxygen barrier polymer film and featuring, for example, a printed cathode deposited on an optional, highly conductive carbon printed cathode collector with a printed or a foil strip anode placed adjacent to the cathode. A viscous or gelled electrolyte is dispensed and/or printed in the cell, and a top laminate can then be sealed onto the picture frame. Such a construction could allow the entire cell to be made on a printing press, for example, as well as gives the opportunity to integrate the battery directly with an electronic application, for example.

Claims

1. A flat electrochemical cell for generating an electrical current, comprising:

a first substrate layer comprising a plurality of laminated layers including a first oxide barrier layer having a gas transmission rate that permits gas to escape through said plurality of laminated layers of the first substrate layer;

a second substrate layer;

a cathode layer provided on said first substrate layer or said second substrate layer;

an anode layer provided on the same of said first substrate layer and said second substrate layer as said cathode layer, said anode layer and said cathode layer thereby being arranged substantially co-planar;

a liquid electrolyte in contact with said cathode layer and also in contact with said anode layer; and

said first substrate layer being connected to said second substrate layer to form an inner space containing said electrolyte, wherein

at least one of said anode layer and said cathode layer is formed of a cured or dried ink.

2. The electrochemical cell of claim 1, further comprising a cathode current collector disposed between said cathode layer and the substrate on which the cathode layer is provided.

3. The electrochemical cell of claim 2, further comprising an anode current collector disposed between said anode layer and the substrate on which the anode layer is provided.

4. The electrochemical cell of claim 1, said second substrate layer comprising a plurality of laminated layers including a second oxide barrier layer having a gas transmission rate that permits gas to escape through said plurality of laminated layers of the second substrate layer.

5. The electrochemical cell of claim 1, said electrolyte being a gel electrolyte.

6. The electrochemical cell of claim 1, further comprising a soak up separator soaked with said electrolyte and in contact with both said anode layer and said cathode layer in said inner space.

7. The electrochemical cell of claim 1, said first oxide barrier layer being effective to prevent substantial moisture transmission therethrough.

8. The electrochemical cell of claim 1, said first substrate layer and second substrate layer being connected via a frame disposed therebetween.

9. The electrochemical cell of claim 8, said frame comprising a cured or dried adhesive ink.

10. The electrochemical cell of claim 1, said cathode layer being printed from an aqueous composition comprising about 20-60% manganese dioxide, about 2-25% graphite and about 0.5%-15% of an aqueous solution of comprising about 20-60% polyvinylpyrrolidone and about 0.1-20% of distilled water to provide a dry lay down weight of about 0.03-0.25 grams per square inch.

11. The electrochemical cell of claim 2, said cathode current collector comprising a cured or dried ink printed on said substrate, said cathode comprising a cured or dried ink printed on said cathode current collector.

12. The electrochemical cell of claim 11, said cathode collector layer being printed from a different ink than said cathode layer.

13. The electrochemical cell of claim 1, said first substrate layer further comprising a first heat sealing layer.

14. The electrochemical cell of claim 13, said second substrate layer further comprising a second heat sealing layer.

15. The electrochemical cell of claim 1, each of said anode layer and said cathode layer being formed of a cured or dried ink.

16. The electrochemical cell of claim 1, said cathode layer being printed from an aqueous composition comprising manganese dioxide, graphite and hydroxyl-ethyl cellulose.

17. The electrochemical cell of claim 1, said oxide barrier layer being selected such that its barrier properties are configured to provide a desired gas transmission rate corresponding to a specific application or environment during use.

18. The electrochemical cell of claim 17, said barrier properties being configured to provide a desired gas transmission rate corresponding to a hot, dry environment such that said barrier layer exhibits a low transmission rate to prevent substantial moisture loss from said cell.

19. The electrochemical cell of claim 13, said first substrate layer further comprising a first structural layer whose thickness is selected such that the first substrate layer'"'"'s material properties are configured to provide a desired structural strength corresponding to a specific application or environment during use.

20. The electrochemical cell of claim 1, said cell having a non-rectangular shape.

21. A battery comprising a plurality of electrochemical cells according to claim 1.