High current thin electrochemical cell and methods of making the same

• US 8,574,754 B2
• Filed: 12/18/2008
• Issued: 11/05/2013
• Est. Priority Date: 12/19/2007
• Status: Active Grant

• Current Assignee: Blue Spark Innovations LLC
• Original Assignee: Blue Spark Technologies, Inc.
• Inventors: Tucholski, Gary R.
• Primary Examiner(s): Barcena, Carlos
• Assistant Examiner(s): DIGNAN, MICHAEL L
• Application Number:
  US12/809,844
• Publication Number:
  US 20100266895A1
• Time in Patent Office: 1,783 Days
• Field of Search: 429/185, 429/209, 296/231, 296/234
• US Class Current: 429/185
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0414 by screen printing
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/198 characterised by physical properties, e.g. adhesiveness or hardness
• CPC Class Codes: H01M 6/005 Devices for making primary cells
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

A battery including at least one electrochemical cell for generating an electrical current is provided, along with its method of manufacture. In one example, the electrochemical cell is provided on a first substrate and includes an anode and a plurality of cathodes. At least a portion of said anode is located between an adjacent two of said plurality of cathodes. In one example method of manufacture, the electrochemical cell is made via a printing press process.

Claims

1. A flexible battery including at least one electrochemical cell for generating an electrical current, said battery including:

a first substrate;

a second substrate;

a cathode collector layer provided on said first substrate;

a plurality of cathode layers provided on said cathode collector layer;

an electrically-neutral dielectric layer provided on said cathode collector layer between at least an adjacent two of the plurality of cathode layers;

an anode layer provided on said dielectric layer, said anode layer being electrically insulated from said cathode collector layer by said dielectric layer;

an electrolyte layer comprising a liquid electrolyte in contact with said plurality of cathode layers and said anode layer; and

wherein said first substrate is connected and sealed to said second substrate to form an inner space containing said electrolyte, and also containing at least a major portion of said plurality of cathode layers and at least a major portion of said anode layer within said inner space.

2. The battery of claim 1, wherein the dielectric layer is located equidistant between said two adjacent cathode layers.

3. The battery of claim 2, wherein the anode layer is located equidistant between said two adjacent cathode layers.

4. The battery of claim 1, wherein the cathode collector layer includes a geometry having a length and a width such that the number of squares is generally 3 or less, wherein the number of squares is determined by dividing the cathode collector length by the cathode collector width.

5. The battery of claim 4, wherein the length and width of the cathode collector geometry is such that the number of squares is generally 1, or approaching 1.

6. The battery of claim 1, wherein only one of said plurality of cathode layers and said anode layer is comprised of a dried or cured ink, and wherein the other of said plurality of cathode layers and said anode layer is comprised of a strip of material.

7. The battery of claim 1, further including a frame interposed between said first and second substrate to connect and seal said first substrate to said second substrate to form the inner space.

8. The battery of claim 1, wherein said anode layer comprises dried or cured ink.

9. The battery of claim 8, wherein said anode layer comprises printed zinc.

10. The battery of claim 1, wherein said cathode layers and said anode layer all comprise dried or cured ink.

11. The battery of claim 1, wherein said anode layer comprises a zinc foil applied over said cathode current collector via a pressure sensitive adhesive.

12. The battery of claim 1, wherein said plurality of cathode layers are disposed in a co-planar arrangement.

13. The battery of claim 1, wherein said dielectric layer is provided on said cathode collector layer between and co-planar with said adjacent two cathode layers.

14. The battery of claim 1, wherein the cathode collector layer includes a non-rectilinear geometry having an effective length and an effective width such that the number of squares is generally 3 or less, wherein the number of squares is determined by dividing said effective length by the said effective width.