Battery cell construction

• US 9,444,078 B2
• Filed: 11/27/2013
• Issued: 09/13/2016
• Est. Priority Date: 11/27/2012
• Status: Active Grant

• Current Assignee: Blue Spark Innovations LLC
• Original Assignee: Blue Spark Technologies, Inc.
• Inventors: Tucholski, Gary R.
• Primary Examiner(s): GATEWOOD, DANIEL S
• Application Number:
  US14/091,981
• Publication Number:
  US 20140147723A1
• Time in Patent Office: 1,021 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: H01M 2300/0005 Acid electrolytes
• CPC Class Codes: H01M 2300/0014 Alkaline electrolytes
• CPC Class Codes: H01M 4/08 Processes of manufacture
• CPC Class Codes: H01M 4/12 of consumable metal or alloy electrodes use of alloy compositions as active materials H01M4/38
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: H01M 6/045 characterised by aqueous electrolyte
• CPC Class Codes: H01M 6/06 Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: H01M 6/46 of flat cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A flexible battery includes at least one electrochemical cell for generating an electrical current, including a cathode collector layer, a cathode layer, an anode layer, and an optional anode collector layer, some or all of which are formed of a dried or cured ink. A first substrate includes a pair of opposed side portions. A first electrode contact is provided that is electrically coupled to the cathode collector layer and is disposed along one of the pair of opposed side portions of the first substrate, and a second electrode contact is provided that is electrically coupled to the anode layer and is disposed along the other of the pair of opposed side portions of the first substrate. The cathode collector layer includes a geometry having a height and a width such that the number of squares is approximately 5 or less.

Claims

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

a first substrate including a pair of opposed side portions defining a first side and an opposite second side;

a second substrate;

a cathode collector layer provided on the first substrate along the first side and between the pair of opposed side portions and being formed of a dried or cured ink;

a cathode layer provided on the cathode collector layer and being formed of a dried or cured ink;

an anode layer provided on the first substrate along the second side and between the pair of opposed side portions, wherein the cathode and anode layers are disposed in a co-planar arrangement;

an electrolyte layer including a liquid electrolyte in contact with both of the cathode layer and the anode layer,

wherein the first substrate is connected and sealed to the second substrate by an outer seal area formed around the perimeter of said at least one cell to form an inner space containing the electrolyte, and also containing at least a major portion of the cathode layer and the anode layer within the inner space; and

a first electrode contact that is electrically coupled to the cathode collector layer and is disposed along the first side of the first substrate, and a second electrode contact that is electrically coupled to the anode layer and is disposed along the second side of the first substrate,

wherein the cathode collector layer includes a geometry having a height and a width such that the number of squares is approximately 5 or less, wherein the number of squares is determined by dividing the cathode collector layer height extending in a direction between the first and second sides by the cathode collector layer width extending in a direction along the first side of the first substrate,

wherein the cathode collector layer extends under a top side of the outer seal area along the first side of the first substrate to at least partially form the first electrode contact, and

wherein the first substrate includes a cutout area extending therethrough such that the first electrode contact is exposed through the cutout area after the first substrate is connected and sealed to the second substrate.

2. The flexible battery of claim 1, wherein the cathode collector layer includes a geometry having a height and a width such that the number of squares is approximately 1 or less.

3. The flexible battery of claim 1, further including an anode collector layer provided between the anode layer and the first substrate, wherein the cathode collector layer and the anode collector layer are disposed in a co-planar arrangement.

4. The flexible battery of claim 3, wherein the cathode collector layer is disposed along the first side of the first substrate, and the anode collector layer is disposed along the second side of the first substrate.

5. The flexible battery of claim 4, wherein the second electrode contact that is electrically coupled to the anode collector layer.

6. The flexible battery of claim 3, wherein at least one of the anode layer and the anode collector layer is formed of a dried or cured ink.

7. The flexible battery of claim 6, wherein the anode layer includes printed zinc.

8. The flexible battery of claim 3, wherein the anode collector layer includes a geometry having a height and a width such that the number of squares is approximately 5 or less, wherein the number of squares is determined by dividing the anode collector layer height extending in a direction between the first and second sides by the anode collector layer width extending in a direction along the second side of the first substrate.

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

10. The flexible battery of claim 9, wherein the frame includes at least one of a cured or dried adhesive ink, and a pressure-sensitive adhesive.

11. The flexible battery of claim 1, wherein the first substrate includes a second cutout area extending therethrough such that the second electrode contact is exposed through the second cutout area after the first substrate is connected and sealed to the second substrate.

12. The flexible battery of claim 1, wherein the electrolyte includes an aqueous solution of zinc chloride (ZnCl2).

13. The flexible battery of claim 1, wherein the electrolyte includes an alkaline electrolyte including at least one of sodium hydroxide (NaOH) or potassium hydroxide (KOH).

14. A flexible battery including at least two electrochemical cells for generating an electrical current, the battery including:

a first substrate including a pair of opposed side portions;

a second substrate;

a first electrochemical cell on the first substrate, including a first cathode collector layer, a first cathode on the first cathode collector layer, and a first anode, wherein the first cathode collector layer is provided on the first substrate between the pair of opposed side portions;

a second electrochemical cell on the first substrate, including a second cathode collector layer, a second cathode on the second cathode collector layer, and a second anode, wherein the second cathode collector layer is provided on the first substrate between the pair of opposed side portions;

first and second liquid electrolytes provided, respectively, in contact with the first and second electrochemical cells, wherein the second substrate layer is connected to the first substrate layer to form first and second inner spaces, respectively, containing each of said first and second liquid electrolytes;

a first electrical bridge that electrically couples the first electrochemical cell to the second electrochemical cell in a parallel arrangement; and

a first electrode contact that is electrically coupled to the first cathode collector layer and is disposed along one of the pair of opposed side portions of the first substrate, and a second electrode contact that is electrically coupled to the first anode layer and is disposed along the other of the pair of opposed side portions of the first substrate,

wherein each of the first and second cathode collector layers includes a geometry having a height and a width such that the number of squares is approximately 5 or less, respectively, wherein the number of squares is determined by dividing the respective cathode collector layer height extending in a direction between the pair of opposed side portions by the respective cathode collector layer width extending in a direction along one of the pair of opposed side portions of the first substrate.

15. The flexible battery of claim 14, further including first anode collector layer provided to the first electrochemical cell between the first anode layer and the first substrate, and a second anode collector layer provided to the second electrochemical cell between the second anode layer and the first substrate.

16. The flexible battery of claim 15, wherein the electrical bridge electrically couples the first and second cathode collector layers together, and wherein the battery further includes a second electrical bridge that electrically couples the first and second anode collector layers together.

17. The flexible battery of claim 16, wherein the first electrode contact is provided on the first electrical bridge, and the second electrode contact is provided on the second electrical bridge.

18. The flexible battery of claim 15, wherein each of the first and second anode collector layers includes a geometry having a height and a width such that the number of squares is approximately 5 or less, respectively, wherein the number of squares is determined by dividing the respective anode collector layer height extending in a direction between the pair of opposed side portions by the respective anode collector layer width extending in a direction along one of the pair of opposed side portions of the first substrate.

19. The flexible battery of claim 14, wherein both of the first and second cathode collector layers are disposed along the same one of the pair of opposed side portions of the first substrate, and wherein both of the first and second anodes are disposed along the same other of the pair of opposed side portions of the first substrate.

20. The flexible battery of claim 14, wherein the first cathode and anode layers are disposed in a co-planar arrangement, and wherein the second cathode and anode layers are disposed in a co-planar arrangement.

21. The flexible battery of claim 14, wherein all of said first and second cathode current collectors, first and second cathodes, and first and second anodes include cured or dried inks.

22. The flexible battery of claim 14, further including third and fourth electrochemical cells on the first substrate that each include a cathode collector layer that is electrically coupled to the first and second cathode collector layers.

23. The flexible battery of claim 14, wherein the electrolyte includes an aqueous solution of zinc chloride (ZnCl2).

24. The flexible battery of claim 14, wherein the electrolyte includes an alkaline electrolyte including at least one of sodium hydroxide (NaOH) or potassium hydroxide (KOH).