Method for fabricating a leadless battery employing an alkali metal anode and polymer film inks

• US 5,624,468 A
• Filed: 06/02/1993
• Issued: 04/29/1997
• Est. Priority Date: 06/02/1993
• Status: Expired due to Term

• Current Assignee: Round Rock Research LLC
• Original Assignee: Micron Technology, Inc.
• Inventors: Lake, Rickie C.
• Primary Examiner(s): Maples, John S.
• Application Number:
  US08/071,463
• Time in Patent Office: 1,427 Days
• Field of Search: 429/127, 429/192, 429/162, 429/218, 29/623.1, 29/623.4, 29/623.5
• US Class Current: 29/623.5
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/08 Processes of manufacture
• CPC Class Codes: H01M 4/381 Alkaline or alkaline earth metals elements H01M4/40 takes precedence
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/66 Selection of materials
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/666 in the form of mixed materials H01M4/668 takes precedence
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 4/668 Composites of electroconductive material and synthetic resins
• CPC Class Codes: H01M 4/75 Wires, rods or strips
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/562 characterised by the material
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: H01M 6/181 with polymeric electrolytes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• 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
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating

Abstract

A package and method for fabricating a battery is disclosed. According to the method a first base, preferably comprising a polyester, is provided and a first slot is made thereon. Next, a first conductive thick film ink is printed superjacent the first base which is subsequently cured to form a first conductive layer. Subsequently, a cathode layer is formed superjacent the first conductive layer and the combination is subsequently cured. An electrolyte layer is then formed superjacent the cathode layer, which is subsequently cured to complete the first base. A second base, preferably comprising a polyester, is then provided and a second slot is made thereon. Subsequently, a second conductive thick film ink is printed superjacent the second base which is then cured to form a second conductive layer. Next, a molten alkali metal is fused to the second conductive layer and allowed to solidify and cool. This completes fabrication of the second base. Once both first and second bases are completed, they are properly aligned such that the first pad is exposed through the second slot, and the second pad is exposed through the first slot. Thus, direct electrical contact can be made to both the first and second conductive layers by means of both pads through both slots.

Claims

1. A method of making an anode for a battery, the method comprising the steps of:

providing a nonconductive surface;

forming a conductive layer comprising a polymer superjacent the nonconductive surface; and

fusing an alkali metal to the conductive layer.

2. The method of claim 1 wherein the nonconductive surface is a polymer film.

3. The method of claim 1 wherein the step of forming comprises printing with a polymer ink and curing the ink.

4. The method of claim 1 wherein the step of fusing comprises applying molten lithium to the conductive layer.