Multi-cell battery

• US 8,765,284 B2
• Filed: 05/21/2013
• Issued: 07/01/2014
• Est. Priority Date: 05/21/2012
• Status: Active Grant

• Current Assignee: Blue Spark Innovations LLC
• Original Assignee: Blue Spark Technologies, Inc.
• Inventors: Tucholski, Gary R.
• Primary Examiner(s): Ruddock, Ula C
• Assistant Examiner(s): VAN OUDENAREN, MATTHEW W
• Application Number:
  US13/899,291
• Publication Number:
  US 20130323565A1
• Time in Patent Office: 406 Days
• Field of Search: None
• US Class Current: 429/127
• CPC Class Codes: H01M 10/0427 Button cells
• CPC Class Codes: H01M 10/285 Button cells
• CPC Class Codes: H01M 10/365 Zinc-halogen accumulators
• CPC Class Codes: H01M 12/085 Zinc-halogen cells or batteries
• CPC Class Codes: H01M 50/109 of button or coin shape
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/526 having a layered structure
• 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: Y02E 60/10 Energy storage using batteries

Abstract

A flexible battery includes a first substrate layer with a first cell portion, a second cell portion, and a bridge portion connecting the first and second cell portions. An electrical bridge electrically couples a first electrochemical cell to a second electrochemical cell in series or parallel, and an electrical bridge is flexible and extends across the bridge portion of the first substrate layer. A second substrate layer is connected to the first substrate layer such that both of the first and second electrochemical cells are separately sealed. The flexible battery is configured to be folded over itself along the bridge portion such that the first and second electrochemical cells are arranged in a covering relationship. Optionally, an open gap area is disposed over the bridge portion of the first substrate to facilitate folding the flexible battery over itself along a line extending through the bridge portion.

Claims

1. A flexible battery for generating an electrical current, comprising:

a first substrate layer comprising a first cell portion, a second cell portion, and a bridge portion connecting the first and second cell portions;

a first electrochemical cell on the first cell portion, comprising a first anode and a first cathode;

a second electrochemical cell on the second cell portion, comprising a second anode and a second cathode;

an electrical bridge that electrically couples the first electrochemical cell to the second electrochemical cell in series or parallel,

wherein the electrical bridge is flexible and extends across the bridge portion of the first substrate layer;

first and second liquid electrolytes provided, respectively, in contact with the first and second electrochemical cells; and

a second substrate layer being connected to said first substrate layer to contain each of said first and second liquid electrolytes such that both of the first and second electrochemical cells are separately sealed,

wherein the flexible battery is configured to be folded over itself along the bridge portion such that the first and second electrochemical cells are arranged in a covering relationship, and

wherein said first substrate layer and second substrate layer are connected via a frame disposed therebetween.

2. The battery of claim 1, wherein the electrical bridge electrically couples one of the first cathode and first anode of the first electrochemical cell to one of the second cathode and second anode of the second electrochemical cell.

3. The battery of claim 2, wherein the electrical bridge comprises a current collector provided on said first substrate and underneath both of said one of the first cathode and first anode of the first electrochemical cell and said one of the second cathode and second anode of the second electrochemical cell.

4. The battery of claim 3, wherein all of said current collector, first and second cathodes, and first and second anodes are comprised of cured or dried inks.

5. The battery of claim 2, further comprising a flexible conductive layer provided on top of said electrical bridge to thereby mechanically and/or electrically strengthen the electrical bridge.

6. The battery of claim 1, further comprising a first electrode contact that is electrically coupled to the first electrochemical cell, and a second electrode contact that is electrically coupled to the second electrochemical cell.

7. The battery of claim 6, wherein at least one of the first and second electrode contacts extends a distance outwards and is configured to be folded over one of the first and second substrates.

8. The battery of claim 6, wherein one of the first and second substrates comprises a cutout area extending therethrough such that one of the first and second electrode contacts is exposed through the cutout area.

9. The battery of claim 1, wherein said frame comprises an open gap disposed between the first substrate layer and second substrate layer, and over the bridge portion of the first substrate, to thereby facilitate folding the flexible battery over itself along a line extending through the bridge portion.

10. The battery of claim 9, wherein said frame comprises a cured or dried adhesive ink.

11. A flexible battery for generating an electrical current, comprising:

a first substrate layer comprising a first cell portion, a second cell portion, and a bridge portion connecting the first and second cell portions;

a current collector layer provided at least partially on both of the first and second cell portions of first substrate layer, and extending across the bridge portion;

a first cathode layer and a first anode layer provided on the first cell portion of the first substrate to form a first electrochemical cell;

a second cathode layer and a second anode layer provided on the second cell portion of the first substrate to form a second electrochemical cell,

wherein one of the cathode layer and anode layer of the first electrochemical cell, and one of the cathode layer and anode layer of the second electrochemical cell, are both provided on the current collector layer;

a first electrode contact coupled to one of the cathode layer and anode layer of the first electrochemical cell;

a second electrode contact coupled to one of the cathode layer and anode layer of the second electrochemical cell;

first and second liquid electrolytes provided, respectively, in contact with the first and second electrochemical cells; and

a second substrate layer being connected to said first substrate layer to form first and second inner spaces, respectively, containing each of said first and second liquid electrolytes,

wherein the flexible battery is configured to be folded over itself along the bridge portion such that the first and second electrochemical cells are arranged in a covering relationship over each other, and

wherein said first substrate layer and second substrate layer are connected via a frame disposed therebetween.

12. The battery of claim 11, wherein all of said cathode current collector, first and second cathodes, and first and second anodes are comprised of cured or dried inks.

13. The battery of claim 11, further comprising a flexible conductive layer provided on top of said current collector layer to thereby mechanically and/or electrically strengthen the current collector layer over the bridge portion.

14. The battery of claim 11, wherein at least one of the first and second electrode contacts extends a distance outwards and is configured to be folded over one of the first and second substrates.

15. The battery of claim 11, wherein one of the first and second substrates comprises a cutout area extending therethrough such that one of the first and second electrode contacts is exposed through the cutout area.

16. The battery of claim 11, wherein said frame comprises an open gap disposed between the first substrate layer and second substrate layer, and over the bridge portion of the first substrate to thereby facilitate folding the flexible battery over itself along a line extending through the bridge portion.

17. A flexible battery for generating an electrical current, comprising:

a first substrate layer comprising a first cell portion, a second cell portion, and a bridge portion connecting the first and second cell portions;

a first electrochemical cell on the first cell portion;

a second electrochemical cell on the second cell portion;

an electrical bridge that electrically couples the first electrochemical cell to the second electrochemical cell in series or parallel,

wherein the electrical bridge is flexible and extends across the bridge portion of the first substrate layer;

first and second liquid electrolytes provided, respectively, in contact with the first and second electrochemical cells; and

a second substrate layer being connected to said first substrate layer to contain each of said first and second liquid electrolytes such that both of the first and second electrochemical cells are separately sealed,

wherein the flexible battery is configured to be folded over itself along the bridge portion such that the first and second electrochemical cells are arranged in a covering relationship; and

an open gap area disposed between the first substrate layer and second substrate layer, and over the bridge portion of the first substrate, to thereby facilitate folding the flexible battery over itself along a line extending through the bridge portion.

18. The battery of claim 17, wherein said first substrate layer and second substrate layer are connected via a frame disposed therebetween that separately encloses each of said first electrochemical cell and said second electrochemical cell, and wherein said frame extends along the bridge portion of the first substrate and comprises said open gap.

19. The battery of claim 1, wherein the electrical bridge comprises a current collector layer provided at least partially on both of the first and second cell portions of first substrate layer, and extending across the bridge portion.

20. The battery of claim 19, wherein one of the cathode layer and anode layer of the first electrochemical cell, and one of the cathode layer and anode layer of the second electrochemical cell, are both provided on the current collector layer.

21. The battery of claim 19, wherein all of said current collector layer, first and second cathodes, and first and second anodes are comprised of cured or dried inks.

22. The battery of claim 19, further comprising a first electrode contact that is electrically coupled to the first electrochemical cell, and a second electrode contact that is electrically coupled to the second electrochemical cell,

wherein one of the first and second substrates comprises a cutout area extending therethrough such that one of the first and second electrode contacts is exposed through the cutout area.

23. The battery of claim 1, wherein the frame comprises an exterior geometry that substantially corresponds to an overall geometry of the battery, and an interior area that provides the first and second inner spaces, respectively, of the first and second electrochemical cells.

24. The battery of claim 1, further comprising a pair of frames that are each separately provided over one of the first and second electrochemical cells.

25. The battery of claim 9, wherein the frame comprises an approximately figure-8 geometry with a rectangular extension that extends along the bridge portion of the first substrate layer.

26. The battery of claim 9, wherein a portion of the frame is removed about the bridge portion to form the open gap.

27. The battery of claim 1, wherein the first and second cathodes are connected by a first electrical bridge, and the first and second anodes are connected by a separate second electrical bridge to thereby provide the flexible battery in a parallel cell arrangement, and wherein both of the first and second electrical bridges are flexible and extend across the bridge portion of the first substrate layer.

28. The battery of claim 27, wherein the first electrical bridge comprises a cathode current collector, and the second electrical bridge comprises an anode current collector.

29. The battery of claim 11, wherein the current collector layer is flexible and extends across the bridge portion of the first substrate layer.

30. The battery of claim 11, wherein the first and second cathodes are provided on the current collector layer, and the first and second anodes are provided on a separate anode current collector to thereby provide the flexible battery in a parallel cell arrangement.

31. The battery of claim 16, wherein a portion of the frame is removed about the bridge portion to form the open gap.

32. The battery of claim 17, wherein the first electrochemical comprises a first anode and a first cathode, and the second electrochemical cell comprises a second anode and a second cathode, and wherein the electrical bridge electrically couples one of the first cathode and first anode of the first electrochemical cell to one of the second cathode and second anode of the second electrochemical cell.

33. The battery of claim 32, wherein the electrical bridge comprises a current collector provided on said first substrate and underneath both of said one of the first cathode and first anode of the first electrochemical cell and said one of the second cathode and second anode of the second electrochemical cell.

34. The battery of claim 33, wherein all of said current collector, first and second cathodes, and first and second anodes are comprised of cured or dried inks.

35. The battery of claim 32, wherein the first and second cathodes are connected by a first electrical bridge, and the first and second anodes are connected by a separate second electrical bridge to thereby provide the flexible battery in a parallel cell arrangement.

36. The battery of claim 17, further comprising a flexible conductive layer provided on top of said electrical bridge to thereby mechanically and/or electrically strengthen the electrical bridge.

37. The battery of claim 17, further comprising a first electrode contact that is electrically coupled to the first electrochemical cell, and a second electrode contact that is electrically coupled to the second electrochemical cell.

38. The battery of claim 18, wherein a portion of the frame is removed about the bridge portion to form the open gap.

39. The battery of claim 37, wherein at least one of the first and second electrode contacts extends a distance outwards and is configured to be folded over one of the first and second substrates.

40. The battery of claim 37, wherein one of the first and second substrates comprises a cutout area extending therethrough such that one of the first and second electrode contacts is exposed through the cutout area.