Polymer-lithium batteries and improved methods for manufacturing batteries

• US RE36,843 E
• Filed: 09/26/1996
• Issued: 08/29/2000
• Est. Priority Date: 06/21/1993
• Status: Expired due to Term

• Current Assignee: Round Rock Research LLC
• Original Assignee: Micron Technology, Inc.
• Inventors: Lake, Rickie C., Tuttle, John R.
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US08/721,106
• Time in Patent Office: 1,433 Days
• Field of Search: 429/124, 429/127, 429/130, 429/162, 429/192, 429/246, 429/306, 29/623.3, 29/623.4, 29/623.5
• US Class Current: 429/124
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/0402 Methods of deposition of the material
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0414 by screen printing
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/0483 by methods including the handling of a melt H01M4/0438, take precedence
• CPC Class Codes: H01M 6/188 Processes of manufacture
• 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: Y10T 29/49112 including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

Improved polymer batteries and improved methods of manufacturing such polymer batteries are provided. One improved method of manufacture involves the formation of a laminated array structure that includes a number of individual battery cells. After formation of the laminated array the individual batteries are singulated from the array by cutting, shearing or stamping. Other manufacturing improvements include the use of a printing process (e.g. stenciling) to form the cathodes, the use of permanent mask layers to contain and insulate the cathodes and anodes, and the use of a molten lithium deposition process for forming the anodes.

Claims

1. A method for manufacturing thin batteries, comprising:

forming a cathode layer by depositing a cathode material onto a cathode substrate in a pattern to form cathodes;

separating the cathodes with an insulating cathode mask;

forming a separator/electrolyte layer of a solid electrolyte material in contact with the cathodes;

forming an anode layer by depositing an anode material as a patterned solder on an anode substrate to form anodes for contact with the separator/electrolytic layer;

separating the anodes with an insulated anode mask;

combining the separate layers together to form a laminated array structure containing multiple battery cells; and

singulating individual battery cells from the laminated array structure.

2. The method as claimed in claim 1 and wherein the cathode layer is formed by depositing a cathode material on the cathode substrate in a discrete pattern using a printing process.

3. The method as claimed in claim 2 and wherein the anode material is lithium.

4. The method as claimed in claim 1 and further comprising forming a second cathode layer, a second separator/electrolyte layer and a second anode layer to form multiple stacked battery cells.

5. The method as claimed in claim 1 and wherein the cathode substrate comprises a patterned metal foil.

7. The method as claimed in claim 1 and wherein the cathode layer is formed by depositing an insulating paint having a pattern of openings on the cathode substrate and then depositing the cathode material into the openings.

8. The method as claimed in claim 1 and wherein singulating the individual battery cells is by cutting, shearing or stamping.

6. The method as claimed in claim i and wherein the cathode layer is formed by depositing a cathode material on the cathode substrate using a stencil to pattern the cathode material.

9. A method of manufacturing thin polymer batteries by forming a laminated array containing multiple battery cells by the steps comprising;

forming a cathode substrate layer of a conductive material;

forming cathodes for the battery cells by depositing a cathode material in a discrete pattern on the cathode substrate layer and separating the cathodes with a cathode mask;

placing a separator/insulator layer in contact with the cathodes;

forming an anode substrate layer of a conductive material;

forming anodes for the battery cells by depositing a molten anode material in a discreet pattern on the anode substrate layer and separating the anodes with an anode mask;

placing the anodes in contact with the separator/insulator layer; and

singulating the individual battery cells from the laminated array.

10. The method as claimed in claim 9 and wherein the cathode material is deposited on the cathode substrate using a printing process.

11. The method as claimed in claim 10 and wherein the printing process uses stencils to pattern the cathode material.

12. The method as claimed in claim 11 and wherein the anodes are formed by depositing molten lithium solder in a pattern on the anode substrate.

13. The method as claimed in claim 12 and wherein the cathode substrate is formed of a sheet of patterned metal.

14. The method as claimed in claim 12 and wherein the laminated array is formed with more than one layer of anodes and more than one layer of cathodes to form stacked battery cells.

15. The method as claimed in claim 12 and wherein the cathode mask is formed with studs to prevent the cathodes from being compressed and shorted.

16. The method as claimed in claim 12 and wherein the anode substrate is formed of a sheet of patterned metal.

17. A method of forming a thin battery comprising the steps of:

providing a cathode substrate layer;

depositing a cathode material on the substrate layer using a first stencil formed with a first opening and printing the cathode material through the first opening onto the substrate layer to form a cathode;

depositing an electrolytic material on the cathode using a second stencil formed with a second opening and printing the electrolytic material through the second opening onto the cathode; and

forming an anode on the electrolytic material.

18. The method as claimed in claim 17 and wherein the second opening is larger than the first opening and the electrolytic material overlaps opposite sides of the cathode.

19. A thin battery comprising:

a cathode substrate formed of a conductive material;

a cathode deposited in a discrete pattern on the cathode substrate by depositing a cathode material on the cathode substrate using a printing process;

a cathode mask formed on the cathode substrate for separating and insulating the cathode said cathode mask including studs to prevent compression and shorting of the cathode;

a separator/electrolyte layer in contact with the cathode;

an anode deposited in a discrete pattern on a conductive anode substrate in contact with the separator/electrolyte layer and formed by depositing a molten anode material onto the anode substrate; and

an anode mask formed on the anode substrate for separating and insulating the anode.

20. The thin battery as claimed in claim 19 and wherein the printing process for depositing the cathode material uses stencils.

21. The thin battery as claimed in claim 19 and wherein the anode is formed of lithium applied as a patterned solder.

22. The thin battery as claimed in claim 19 and wherein the printing process for depositing the cathode material uses insulating paint deposited onto the cathode substrate.

23. The thin polymer battery as claimed in claim 19 and wherein the battery further comprises:

a second cathode formed of a cathode material deposited on the anode substrate by a printing process and insulated by a second cathode mask;

a second separator/electrolyte layer in contact with the second cathode; and

a second anode in contact with the second separator/electrolyte layer and formed of an anode material deposited on a second anode substrate.

24. The thin polymer battery as claimed in claim 19 and wherein a plurality of identical batteries are assembled in a laminated array and then singulated from the array.

25. The thin battery as claimed in claim 19 and wherein the separator/electrolyte layer is stenciled onto the cathode. .Iadd.

26. A method for manufacturing batteries comprising:

depositing a cathode layer onto a cathode substrate in a pattern to form cathodes;

separating the cathodes with an insulating cathode mask;

depositing an anode layer on an anode substrate in a pattern to form anodes;

separating the anodes with an insulated anode mask;

providing a separator/electrolyte layer between said cathodes and said anodes; and

combining the separate layers together to form a laminated array structure containing multiple battery cells. .Iaddend..Iadd.27. The method as claimed in claim 26 and further including singulating individual battery cells from the laminated array structure. .Iaddend..Iadd.28. The method as claimed in claim 26 and wherein the cathode layer is formed by depositing a cathode material on the cathode substrate in a discrete pattern using a printing process. .Iaddend..Iadd.29. The method as claimed in claim 26, and wherein the anode material is lithium. .Iaddend..Iadd.30. The method as claimed in claim 26 and further comprising forming a second cathode layer, providing a second separator/electrolyte layer and forming a second anode layer to form multiple stacked battery cells. .Iaddend..Iadd.31. The method as claimed in claim 26 and wherein the cathode substrate comprises a patterned metal foil. .Iaddend..Iadd.32. The method as claimed in claim 26 and wherein the cathode layer is formed by depositing a cathode material on the cathode substrate using a stencil to pattern the cathode

27. material. .Iaddend..Iadd.33. The method as claimed in claim 26 and wherein the cathode layer is formed by depositing an insulating paint having a pattern of openings on the cathode substrate and then depositing the cathode material into the openings. .Iaddend..Iadd.34. The method as claimed in claim 27 and wherein singulating the individual battery cells is by cutting shearing or stamping. .Iaddend..Iadd.35. A method of manufacturing batteries comprised of a laminated array containing multiple battery cells comprising

providing a cathode substrate layer of a conductive material;

depositing a cathode material in a pattern to form cathodes on the cathode substrate layer and separating the cathodes with a cathode mask;

placing a separator/insulator layer in contact with the cathodes;

providing an anode substrate layer of a conductive material;

depositing an anode material in a pattern to form anodes on the anode substrate layer and separating the anodes with an anode mask; and

placing the anodes in contact with the separator/insulator layer. .Iaddend..Iadd.36. The method as claimed in claim 35 and further including singulating the individual battery cells from the laminated array. .Iaddend..Iadd.37. The method as claimed in claim 35 and wherein the cathode material is deposited on the cathode substrate layer using a printing process. .Iaddend..Iadd.38. The method as claimed in claim 37 and wherein the printing process uses stencils to pattern the cathode material. .Iaddend..Iadd.39. The method as claimed in claim 35 and wherein the anodes are formed by depositing molten lithium solder in a pattern on

28. the anode substrate layer. .Iaddend..Iadd.40. The method as claimed in claim 35 and wherein the cathode substrate layer is formed of a sheet of patterned metal. .Iaddend..Iadd.41. The method as claimed in claim 35 and wherein the laminated array is formed with more than one layer of anodes and more than one layer of cathodes to form stacked battery cells. .Iaddend..Iadd.42. The method as claimed in claim 35 and wherein the cathode mask is formed with studs to prevent the cathodes from being compressed and shorted. .Iaddend..Iadd.43. The method as claimed in claim 35 and wherein the anode substrate layer is formed of a sheet of patterned metal. .Iaddend..Iadd.44. A method of forming a battery comprising the steps of:

providing a cathode substrate layer;

depositing a cathode material on the cathode substrate layer using a printing process to form a cathode;

depositing an electrolytic material on the cathode using a printing process; and

forming an anode on the electrolytic material. .Iaddend..Iadd.45. The method as claimed in claim 44 and wherein said depositing a cathode material includes using a first stencil formed with a first opening and printing the cathode material through the first opening onto the cathode substrate layer and said depositing an electrolytic material includes using a second stencil formed with a second opening and printing the electrolytic material through the second opening onto the cathode. .Iaddend..Iadd.46. The method as claimed in claim 45 and wherein the second opening is larger than the first opening and the electrolytic

29. material overlaps opposite sides of the cathode. .Iaddend..Iadd.47. A battery comprising:

a cathode substrate comprised of a conductive material;

a cathode on the cathode substrate;

a cathode mask on the cathode substrate separating and insulating the cathode, said cathode mask including studs;

a separator/electrolyte layer in contact with the cathode;

an anode on a conductive anode substrate in contact with the separator/electrolyte layer; and

an anode mask on the anode substrate separating and insulating the anode. .Iaddend..Iadd.48. The battery as claimed in claim 47 and wherein the anode is comprised of lithium. .Iaddend..Iadd.49. The battery as claimed in claim 47 and wherein the battery further comprises;

a second cathode on the anode substrate and insulated by a second cathode mask;

a second separator/electrolyte layer in contact with the second cathode; and

a second anode in contact with the second separator/electrolyte layer on a second anode substrate. .Iaddend..Iadd.50. The battery as claimed in claim 47 and further including a plurality of substantially identical batteries assembled in a laminated array. .Iaddend..Iadd.51. A method of forming a battery comprising the steps of;

providing an anode substrate layer;

depositing an anode material on the anode substrate layer using a printing process to form at least one anode;

depositing an electrolytic material on the at least one anode using a printing process; and

forming at least one cathode on the electrolytic material.

30. Iaddend..Iadd. . The method as claimed in claim 51 and wherein said depositing an anode material includes using a first stencil formed with a first opening and printing the anode material through the first opening onto the anode substrate layer and said depositing an electrolytic material includes using a second stencil formed with a second opening and printing the electrolytic material through the second opening onto the anode. .Iaddend..Iadd.53. The method as claimed in claim 52 and wherein the second opening is larger than the first opening and the electrolytic material overlaps opposite sides of the anode. .Iaddend..Iadd.54. A battery, comprising:

a cathode substrate;

a anode substrate;

a cathode on said cathode substrate;

a cathode mask on said cathode substrate, said cathode mask including a plurality of studs to prevent compression and shorting of said cathode;

a separator/electrolyte layer in contact with said cathode; and

an anode on said anode substrate and in contact with said separator/electrolyte layer. .Iaddend..Iadd.55. The battery of claim 54, further including an anode mask on said anode substrate. .Iaddend..Iadd.56. The battery of claim 55, wherein said anode mask includes a plurality of studs to prevent compression and shorting of said anode. .Iaddend..Iadd.57. The battery as claimed in claim 54 and wherein

31. the anode is comprised of lithium. .Iaddend..Iadd.58. The battery as claimed in claim 54 and wherein the battery further comprises:

a second cathode on the anode substrate and insulated by a second cathode mask;

a second separator/electrolyte layer in contact with the second cathode; and

a second anode in contact with the second separator/electrolyte layer on a second anode substrate. .Iaddend..Iadd.59. The battery as claimed in claim 54 and further including a plurality of substantially identical batteries assembled in a laminated array. .Iaddend..Iadd.60. A method for manufacturing batteries, comprising;

forming a pattern of cathodes on a cathode substrate;

separating the cathodes with an insulating cathode mask;

forming a pattern of anodes on an anode substrate;

separating the anodes with an insulated anode mask; and

providing a separator/electrolyte layer between and in contact with said cathodes and said anodes. .Iaddend..Iadd.61. The method as claimed in claim 60 and wherein the cathodes are formed by depositing a cathode material on the cathode substrate in a discrete pattern using a printing process. .Iaddend..Iadd.62. The method as claimed in claim 60, and wherein the anodes are formed from lithium. .Iaddend..Iadd.63. The method as claimed in claim 60 and further comprising forming a second pattern of cathodes providing a second separator/electrolyte layer and forming a second pattern of anodes to form multiple stacked battery cells.

32. Iaddend..Iadd.64. The method as claimed in claim 60 and wherein the cathode substrate comprises a patterned metal foil. .Iaddend..Iadd.65. The method as claimed in claim 60 and wherein the cathode layer is formed by depositing a cathode material on the cathode substrate using a stencil to pattern the cathode material. .Iaddend..Iadd.66. The method as claimed in claim 60 and wherein the cathodes are formed by depositing an insulating paint having a pattern of openings on the cathode substrate and then depositing a cathode material into the openings. .Iaddend..Iadd.67. A method for manufacturing batteries, comprising:

providing a conductive separator layer having a first side and it second side;

forming a plate of cathodes an said first side of said separator layer;

forming a pattern of anodes on said second side of said separator layer;

providing a cathode substrate over said cathodes; and

providing an anode substrate over said anodes. .Iaddend..Iadd.68. The method of claim 67, further including separating said cathodes with an insulating cathode mask. .Iaddend..Iadd.69. The method of claim 67, further including separating said anodes with an insulating anode mask.

33. Iaddend..Iadd.70. The method as claimed in claim 67 and wherein the separator comprises a metal foil. .Iaddend.