Thin printable electrochemical cell utilizing a "picture frame" and methods of making the same
AssigneeBlue Spark Technologies, Inc.
InventorGary Tucholski
Life of this patent
Estimating the term…
Abstract
A thin printed flexible electrochemical cell, and its method of manufacture, using a “picture frame” structure sealed, for example, with a high moisture and oxygen barrier polymer film and featuring, for example, a printed cathode deposited on an optional, highly conductive carbon printed cathode collector with a printed or a foil strip anode placed adjacent to the cathode. A viscous or gelled electrolyte is dispensed and/or printed in the cell, and a top laminate can then be sealed onto the picture frame. Such a construction could allow the entire cell to be made on a printing press, for example, as well as gives the opportunity to integrate the battery directly with an electronic application, for example.
Claims57
A device comprising a flat, thin electrochemical cell for generating an electrical current, said cell including:
- a first substrate layer;
- a second substrate layer;
- a cathode layer provided on at least one of said first substrate layer and said second substrate layer;
- an anode layer provided on at least one of said first substrate layer and said second substrate layer;
- an electrolyte layer in contact with said cathode layer and also in contact with said anode layer;
- and
- a frame provided substantially around a perimeter of said cell and connecting said lower substrate layer to said upper substrate layer, wherein
- said frame is substantially thicker than each one of said cathode layer, said anode layer, and said electrolyte layer.
A device comprising a flat electrochemical cell for generating an electrical current, said cell including:
- a first substrate layer comprised of a plurality of laminated layers;
- a second substrate layer;
- a cathode layer provided on at least one of said first substrate layer and said second substrate layer;
- an anode layer provided on at least one of said first substrate layer and said second substrate layer;
- an electrolyte layer comprising a viscous liquid in contact with said cathode layer and also in contact with said anode layer;
- and
- a frame connecting and sealing said lower substrate layer to said upper substrate layer to form an inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space, wherein
- at least one of said anode layer and said cathode layer are comprised of a cured or dried ink.
A battery comprising at least one cell, said at least one cell including:
- a first substrate layer comprised of a plurality of laminated layers including at least a structural layer, an oxide barrier layer, and a sealing layer;
- a second substrate layer comprised of said plurality of laminated layers;
- a cathode collector layer provided on at least one of said first substrate layer and said second substrate layer;
- a cathode layer provided on said cathode collector layer;
- an anode layer provided on at least one of said first substrate layer and said second substrate layer or provided on an anode collector layer provided on at least one of said first substrate layer and said second substrate layer;
- an electrolyte layer including an electrolyte in contact with said anode layer and said cathode layer;
- and
- a frame around a perimeter of said cell for connecting said lower substrate layer to said upper substrate layer to form an inner space for containing said electrolyte within said inner space along with at least a portion of said anode layer and at least a portion of said cathode layer, wherein
- said inner space is substantially sealed off from an exterior of said cell.
A method of manufacturing a device including an electrochemical cell, said method comprising the step of forming said cell, said forming including the steps of:
- providing a first substrate layer and a second substrate layer, at least one of which including a laminated web having a plurality of layers;
- printing one of a cathode layer and an anode layer on one of said first substrate layer and said second substrate layer;
- providing, by printing or some other process, the other of said cathode layer and said anode layer on one of said first substrate layer and said second substrate layer;
- providing a frame on one of said first substrate layer and said second substrate layer;
- providing an electrolyte layer, said electrolyte layer comprising a viscous liquid;
- and
- connecting the other of said first substrate layer and said second substrate layer to said frame to form an inner substantially sealed space containing said cathode layer, said anode layer, and said electrolyte layer.
Dependencies are inferred from the claim text.