Thin film battery assemblies

• US 9,843,066 B2
• Filed: 05/26/2015
• Issued: 12/12/2017
• Est. Priority Date: 05/27/2014
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Snyder, Shawn William, Menzel, Brian, Neudecker, Bernd Jurgen, Yumiba, Keiichiro, Scales, Timothy Wallen
• Primary Examiner(s): Cantelmo, Gregg
• Application Number:
  US14/722,059
• Publication Number:
  US 20150349370A1
• Time in Patent Office: 931 Days
• CPC Class Codes: H01M 10/02 Details of electrodes H01M4/00; of non-active parts H01M50/00
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/05 Accumulators with non-aqueous electrolyte H01M10/39 takes precedence
• 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 2300/0068 inorganic
• CPC Class Codes: H01M 50/533 characterised by the shape of the leads or tabs
• CPC Class Codes: H01M 50/54 Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges
• 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

Solid-state battery structures and methods of manufacturing solid-state batteries, such as thin-film batteries, are disclosed. More particularly, embodiments relate to solid-state batteries having an intermediate adhesive layer between several electrochemical cells. In an embodiment, an anode current collector at least partially fills a notch in a periphery of the intermediate adhesive layer. Other embodiments are also described and claimed.

Claims

1. An electrochemical device, comprising:

a first electrochemical cell having a first electrolyte layer between a first anode layer and a first cathode layer;

a second electrochemical cell having a second electrolyte layer between a second anode layer and a second cathode layer;

an adhesive layer between the first anode layer and the second anode layer, wherein the adhesive layer includes a notch in a periphery; and

an anode current collector electrically connected to the first and second anode layers and at least partially filling the notch between the first anode layer and the second anode layer.

2. The electrochemical device of claim 1, wherein the anode current collector includes a first portion disposed within the notch between the first anode layer and the second anode layer, and a second portion positioned outward of the periphery of the adhesive layer.

3. The electrochemical device of claim 2, wherein the first portion is adjacent to an edge of the adhesive layer extending around the notch.

4. The electrochemical device of claim 3, wherein the edge extending around the notch conforms to the first portion of the anode current collector.

5. The electrochemical device of claim 4, wherein the first portion of the anode current collector contacts the edge extending around the notch.

6. The electrochemical device of claim 1, wherein the adhesive layer and the anode current collector have a same thickness separating the first anode layer from the second anode layer.

7. The electrochemical device of claim 1, wherein the adhesive layer includes a pressure sensitive adhesive.

8. The electrochemical device of claim 1, wherein the first anode layer and the second anode layer directly contact a portion of the anode current collector at least partially filling the notch between the first anode layer and the second anode layer.

9. An electrochemical device, comprising:

a first electrochemical cell having a first electrolyte layer between a first anode layer and a first cathode layer, and a first sidewall along a first outer edge of the first cathode layer;

a second electrochemical cell having a second electrolyte layer between a second anode layer and a second cathode layer, and a second sidewall along a second outer edge of the second cathode layer;

an adhesive layer between the first anode layer and the second anode layer, wherein the adhesive layer includes a notch in a periphery;

an anode current collector between the first anode layer and the second anode layer, wherein the anode current collector is electrically connected to the first and second anode layers, and wherein the anode current collector at least partially fills the notch between the first anode layer and the second anode layer; and

an insulator on the anode current collector and between the first sidewall and the second sidewall.

10. The electrochemical device of claim 9, wherein the anode current collector includes a first portion disposed within the notch between the first anode layer and the second anode layer, and a second portion positioned outward of the notch.

11. The electrochemical device of claim 10, wherein the first portion of the anode current collector contacts an edge of the adhesive layer extending around the notch.

12. The electrochemical device of claim 9, wherein the adhesive layer and the anode current collector have a same thickness separating the first anode layer and the second anode layer.