# US 5,705,294 A · Method of forming a battery and battery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,705,294 A - Document ID: US5705294A - Status: Granted - Kind: A - Application number: 08/759,190 - Filed: 1996-12-04 - Granted: 1998-01-06 - Earliest claimed: 1995-09-28 - Assignees: Micron Communications, Inc. - Inventors: Rickie C. Lake - Web page: https://patentgrep.com/patent/US5705294A ## CPC - H01M 50/109: of button or coin shape - H01M 6/12: with flat electrodes - H01M 50/186: characterised by the disposition of the sealing members - H01M 50/193: Organic material - Y10T 29/49108: Electric battery cell making - Y10T 29/4911: including sealing - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A button-type battery includes, a) an anode; b) a cathode positioned adjacent to the anode; c) an electrolyte between the anode and the cathode; d) a conductive first terminal housing member in electrical contact with one of the anode or the cathode; the first terminal housing member having a periphery; e) a conductive second terminal housing member in electrical contact with the other of the anode or the cathode; the second terminal housing member having a periphery; f) the first and second terminal housing members forming an enclosed housing which holds and protects the anode, the cathode and the electrolyte; and g) the first and second terminal housing member peripheries being configured together to form an electrically insulative seal which seals the anode, the electrolyte and the cathode within the housing formed by the first and second terminal housing members, the electrically insulative seal comprising cross-linked butyl rubber. The seal can include a gasket which constitutes the cross-linked butyl rubber or other material. The seal can comprise an uncured precursor to butyl rubber. Methods of forming such button-type batteries include in situ curing or forming butyl rubber in place on one of the battery terminals. Alternately, a butyl rubber precursor can be applied to one or both of the battery terminals. ## Claims ### Claim 1 A thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode comprising: a conductive first terminal housing member having a periphery; a conductive second terminal housing member having a periphery; and the first and second terminal housing member peripheries being configured together to form an electrically insulative seal, the electrically insulative seal comprising a chemical precursor to formation of butyl rubber, the chemical precursor comprising depolymerized butyl rubber. ### Claim 2 (depends on 1) The battery of claim 1 wherein the chemical precursor further comprises a compound selected from the group consisting of isobutylene, isoprene and mixtures thereof. ### Claim 3 (depends on 1) The battery of claim 1 wherein the insulative seal consists essentially of the chemical precursor. ### Claim 4 (depends on 1) The battery of claim 1 wherein the insulative seal comprises a gasket, the gasket consisting essentially of a polymer which is not butyl rubber, the chemical precursor being in contact with the gasket. ### Claim 5 (depends on 1) The battery of claim 1 having a total combined thickness of less than 1 millimeter. ### Claim 6 A thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode comprising: a conductive first terminal housing member having a periphery; a conductive second terminal housing member having a periphery; and the first and second terminal housing member peripheries being configured together to form an electrically insulative seal, the electrically insulative seal comprising a pre-formed gasket and a chemical precursor to formation of butyl rubber, the gasket consisting essentially of butyl rubber, the chemical precursor being in contact with the pre-formed butyl rubber gasket. ### Claim 7 A method of forming a thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode, the method comprising the following steps: providing an electrically conductive first terminal housing member material; depositing an electrically insulative chemical precursor material to formation of butyl rubber in a sealing region of the first terminal housing member material, the deposited precursor material being void of any polymerizing or curative agents, the chemical precursor comprising depolymerized butyl rubber; providing the first terminal housing member material into a shape of a desired first terminal housing member; providing an electrically conductive second terminal housing member in facing juxtaposition to the first terminal housing member having the deposited butyl rubber precursor material, the second terminal housing member having a sealing region; providing an anode and a cathode having an electrolyte positioned therebetween; the anode, the cathode, and the electrolyte being positioned intermediate the juxtaposed first and second terminal housing members; the anode being positioned to electrically connect with one of the first or second terminal housing members and the cathode being positioned to electrically connect with the other of the first or second terminal housing members; and joining the sealing regions of the first and second terminal housing members together to form an enclosed battery housing retaining the anode, the cathode and the electrolyte; the electrically insulative butyl rubber precursor material void of any polymerizing and curative agents being interposed between the joined first and second terminal housing members; the precursor material between the joined first and second terminal housing members comprising an electrically insulative fluid-tight seal therebetween. ### Claim 8 (depends on 7) The method of forming a battery of claim 7 wherein the deposited material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material. ### Claim 9 (depends on 7) The method of forming a battery of claim 7 wherein the chemical precursor further comprises a compound selected from the group consisting of isobutylene, isoprene and mixtures thereof. ### Claim 10 (depends on 7) The method of forming a battery of claim 7 wherein the insulative fluid-tight seal consists essentially of the chemical precursor material. ### Claim 11 (depends on 7) The method of forming a battery of claim 7 wherein the insulative fluid-tight seal comprises a gasket, the gasket consisting essentially of a polymer which is not butyl rubber, the depositing step comprising applying the chemical precursor material onto the gasket. ### Claim 12 (depends on 7) The method of forming a battery of claim 7 wherein the deposited precursor material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material; and wherein the insulative fluid-tight seal consists essentially of the chemical precursor material. ### Claim 13 (depends on 7) The method of forming a battery of claim 7 wherein the deposited precursor material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material; and wherein the insulative fluid-tight seal comprises a pre-formed gasket, the gasket consisting essentially of butyl rubber, the depositing step comprising applying the chemical precursor material onto the pre-formed butyl rubber gasket. ### Claim 14 (depends on 7) The method of forming a battery of claim 7 wherein the deposited precursor material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material; and wherein the insulative fluid-tight seal comprises a gasket, the gasket consisting essentially of a polymer which is not butyl rubber, the chemical precursor material being in contact with the gasket. ### Claim 15 (depends on 7) The method of forming a battery of claim 7 wherein the depositing step occurs before the first terminal housing member material is provided into the desired first terminal housing member shape. ### Claim 16 A method of forming a thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode, the method comprising the following steps: providing an electrically conductive first terminal housing member material; depositing an electrically insulative chemical precursor material to formation of butyl rubber in a sealing region of the first terminal housing member material, the deposited precursor material being void of any polymerizing or curative agents; providing the first terminal housing member material into a shape of a desired first terminal housing member; providing an electrically conductive second terminal housing member in facing juxtaposition to the first terminal housing member having the deposited butyl rubber precursor material, the second terminal housing member having a sealing region; providing an anode and a cathode having an electrolyte positioned therebetween; the anode, the cathode, and the electrolyte being positioned intermediate the juxtaposed first and second terminal housing members; the anode being positioned to electrically connect with one of the first or second terminal housing members and the cathode being positioned to electrically connect with the other of the first or second terminal housing member; providing a pre-formed gasket between the first and second terminal housing members, the gasket consisting essentially of butyl rubber, the depositing step comprising applying the chemical precursor material onto the pre-formed butyl rubber gasket; and joining the sealing regions of the first and second terminal housing members together to form an enclosed battery housing retaining the anode, the cathode and the electrolyte; the electrically insulative butyl rubber precursor material void of any polymerizing and curative agents being interposed between the joined first and second terminal housing members; the precursor material and pre-formed gasket between the joined first and second terminal housing members comprising an electrically insulative fluid-tight seal therebetween. ### Claim 17 A method of forming a thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode, the method comprising the following steps: providing an electrically conductive first terminal housing member material; forming the first terminal housing member material into a shape of a desired first terminal housing member; after forming the first terminal housing member into the shape of a desired first terminal housing member, depositing an electrically insulative chemical precursor material to formation of butyl rubber in a sealing region of the first terminal housing member material the deposited precursor material being void of any polymerizing or curative agents; providing an electrically conductive second terminal housing member in facing juxtaposition to the first terminal housing member having the deposited butyl rubber precursor material, the second terminal housing member having a sealing region; providing an anode and a cathode having an electrolyte positioned therebetween; the anode, the cathode, and the electrolyte being positioned intermediate the juxtaposed first and second terminal housing members; the anode being positioned to electrically connect with one of the first or second terminal housing members and the cathode being positioned to electrically connect with the other of the first or second terminal housing members; and joining the sealing regions of the first and second terminal housing members together to form an enclosed battery housing retaining the anode, the cathode and the electrolyte; the electrically insulative butyl rubber precursor material void of any polymerizing and curative agents being interposed between the joined first and second terminal housing members; the precursor material between the joined first and second terminal housing members comprising an electrically insulative fluid-tightseal therebetween. ### Claim 18 A method of forming a thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode, the method comprising the following steps: providing an electrically conductive first terminal housing member material; depositing an uncured electrically insulative chemical precursor material to formation of butyl rubber in a sealing region of the first terminal housing member material, the deposited uncured precursor material comprising a curative and polymerizing agent capable of curing the material into polymerized cross-linked butyl rubber, and in situ curing of the chemical precursor material into butyl rubber; providing the first terminal housing member material into a shape of a desired first terminal housing member; providing an electrically conductive second terminal housing member in facing juxtaposition to the first terminal housing member having the deposited butyl rubber precursor, the second terminal housing member having a sealing region; providing an anode and a cathode having an electrolyte positioned therebetween; the anode, cathode, and electrolyte being positioned intermediate the juxtaposed first and second terminal housing members; the anode being positioned to electrically connect with one of the first or second terminal housing members and the cathode being positioned to electrically connect with the other of the first or second terminal housing members; and joining the sealing regions of the first and second terminal housing members together to form an enclosed battery housing retaining the anode, cathode and electrolyte comprising an electrically insulative fluid-tight seal therebetween; the insulative fluid tight seal comprising in situ formed butyl rubber. ### Claim 19 (depends on 18) The method of forming a battery of claim 18 wherein the curing of the deposited chemical precursor material into butyl rubber is substantially complete before the joining step. ### Claim 20 (depends on 18) The method of forming a battery of claim 18 wherein the chemical precursor material is provided to be substantially uncured at the joining step, the curing not being substantially completed until after the joining step. ### Claim 21 (depends on 18) The method of forming a battery of claim 18 wherein the deposited material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material. ### Claim 22 (depends on 18) The method of forming a battery of claim 18 wherein, the deposited precursor material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material; and the curing of the deposited chemical precursor material into butyl rubber is substantially complete before the joining step. ### Claim 23 (depends on 18) The method of forming a battery of claim 18 wherein, the deposited precursor material comprises a viscosity reducing solvent, the method further comprising allowing the viscosity reducing solvent to evaporate after the depositing step to raise the viscosity of the deposited precursor material; and the chemical precursor material is provided to be substantially uncured at the joining step, the curing not being substantially completed until after the joining step. ### Claim 24 (depends on 18) The method of forming a battery of claim 18 wherein the chemical precursor comprises depolymerized butyl rubber. ### Claim 25 (depends on 18) The method of forming a battery of claim 18 wherein, the chemical precursor comprises depolymerized butyl rubber; and the curing of the deposited chemical precursor material into butyl rubber is substantially complete before the joining step. ### Claim 26 (depends on 18) The method of forming a battery of claim 18 wherein, the chemical precursor comprises depolymerized butyl rubber; and the chemical precursor material is provided to be substantially uncured at the joining step, the curing not being substantially completed until after the joining step. ### Claim 27 (depends on 18) The method of forming a battery of claim 18 wherein the insulative seal comprises a pre-formed gasket, the gasket consisting essentially of butyl rubber, the depositing step comprising applying the chemical precursor material onto the pre-formed butyl rubber gasket. ### Claim 28 (depends on 18) The method of forming a battery of claim 18 wherein the insulative seal comprises a gasket, the gasket consisting essentially of a polymer which is not butyl rubber, the depositing step comprising applying the chemical precursor material onto the gasket. ### Claim 29 A method of forming a thin profile battery defined by a thickness which is less than a maximum linear dimension of its anode, the method comprising the following steps: providing a first terminal housing member; providing a pre-formed gasket within the first terminal housing member; depositing an unpolymerized butyl rubber precursor onto the pre-formed gasket; after the depositing, providing an electrically conductive second terminal housing member in facing juxtaposition to the first terminal housing member; providing an anode and a cathode intermediate the juxtaposed first and second terminal housing members; joining the first and second terminal housing members together to form an enclosed battery housing retaining the anode and the cathode and in situ curing of the butyl rubber precursor on the pre-formed gasket. ### Claim 30 (depends on 29) The method of claim 29 wherein the pre-formed gasket comprises butyl rubber. ### Claim 31 (depends on 29) The method of claim 29 wherein the butyl rubber precursor is substantially uncured at the step of joining the first and second terminal housing members, the in situ curing not being substantially completed until after the joining step.