Robust metal film encapsulation
First Claim
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1. A battery comprising:
- a first electrical contact;
a cell structure comprising a cathode, an anode and an electrolyte;
a bonding layer coupled with said first electrical contact and said bonding layer comprising an embedded conductor, wherein said embedded conductor contacts said cell structure and wherein said embedded conductor physically contacts said first electrical contact; and
a second electrical contact;
wherein said bonding layer and said at least one cell structure are sandwiched between said first electrical contact and said second electrical contact; and
wherein said bonding layer comprises a plurality of layers in which the cell structure is at least in part within one of the plurality of layers.
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Abstract
The present invention relates to metal film encapsulation of an electrochemical device. The metal film encapsulation may provide contact tabs for the electrochemical device. The present invention may also include a selectively conductive bonding layer between a contact and a cell structure. The present invention may further include ways of providing heat and pressure resilience to the bonding layer and improving the robustness of the protection for the cell structure.
814 Citations
24 Claims
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1. A battery comprising:
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a first electrical contact; a cell structure comprising a cathode, an anode and an electrolyte; a bonding layer coupled with said first electrical contact and said bonding layer comprising an embedded conductor, wherein said embedded conductor contacts said cell structure and wherein said embedded conductor physically contacts said first electrical contact; and a second electrical contact; wherein said bonding layer and said at least one cell structure are sandwiched between said first electrical contact and said second electrical contact; and wherein said bonding layer comprises a plurality of layers in which the cell structure is at least in part within one of the plurality of layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 16, 22, 23)
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14. A battery comprising:
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a first electrical contact wherein said first electrical contact is a conductor covered at least in part with an electrically insulating film or wherein said first electrical contact is an electronically insulating layer with a conducting insert; a cell structure comprising a cathode, an anode and an electrolyte; a bonding layer coupled with said first electrical contact and said bonding layer comprising an embedded conductor; and a second electrical contact; wherein said bonding layer and said at least one cell structure are sandwiched between said first electrical contact and said second electrical contact; wherein said bonding layer comprises a plurality of layers; and wherein said electrically insulating film comprises materials selected from the group selected from the group of Lipon, BeO, B2O3, BN, borate glass, Al2O3, MN, SiO2, Si3N4, silicate glass, ScOx, TiOx, VOx, CrOx, FeOx, YOx, ZrOx, NbOx, MoOx, HfOx, TaOx, WOx, olyamides, polyimides, polyethylene terephthalates, para-aramids, polyethylenes, high density polytheylenes, Ultra High Molecular Weight (UHMW) polyethylenes, polypropylenes, acrylics, polycarbonates, polyvinyl chlorides, acetal delrin, phenolics, fluoroplastics, polyurethanes, polystyrenes, acrylonitrile-butadiene-styrenes (ABS), Keton PEEK, Tenite resins, and any combination thereof.
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17. A battery comprising:
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at least one cell structure comprising a cathode, an anode and an electrolyte;
an insulating layer comprising a plurality of layers in which the cell structure is at least in part within one of the plurality of layers;at least one embedded conductor positioned inside each of said plurality of layers of said insulating layer wherein said embedded conductor is adapted to act as a first electrical contact and wherein said embedded conductor contacts said cell structure; and a second electrical contact; wherein said at least one cell structure is sandwiched between said insulating layer and said second electrical contact.
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18. A battery comprising:
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a first cell structure and a neighboring cell structure stacked on top of each other;
wherein each said cell structure comprises, a cathode, an anode, an electrolyte, a first electrical contact and a second electrical contact;a bonding layer; wherein said bonding layer is sandwiched between said first electrical contact of said first cell structure and said second electrical contact of said neighboring cell structure;
wherein said boding layer comprises a plurality of layers in which the cell structure is at least in part within one of the plurality of layers; andwherein said bonding layer further comprises at least one embedded conductor and wherein said embedded conductor contacts said cell structure and wherein said embedded conductor physically contacts said first electrical contact. - View Dependent Claims (19, 20, 21)
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24. A battery comprising:
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a first electrical contact; a cell structure comprising a cathode, an anode and an electrolyte; a bonding layer coupled with said first electrical contact and said bonding layer comprising an embedded conductor, wherein said embedded conductor contacts said cell structure; and a second electrical contact; wherein said bonding layer and said at least one cell structure are sandwiched between said first electrical contact and said second electrical contact; and wherein said bonding layer comprises a plurality of layers and wherein said bonding layer comprises printed circuitry embedded within said bonding layer.
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Specification