U.S. patent application number 11/938414 was filed with the patent office on 2008-03-13 for printed battery.
Invention is credited to Jerry Zucker.
Application Number | 20080063931 11/938414 |
Document ID | / |
Family ID | 29549018 |
Filed Date | 2008-03-13 |
United States Patent
Application |
20080063931 |
Kind Code |
A1 |
Zucker; Jerry |
March 13, 2008 |
PRINTED BATTERY
Abstract
A printed battery has a flexible backing sheet, a first
conductive layer printed on said sheet; a first conductive layer
printed on the first conductive layer; a second electrode layer
printed on said first electrode layer; and a second conductive
layer printed on said second electrode layer.
Inventors: |
Zucker; Jerry; (Charleston,
SC) |
Correspondence
Address: |
HAMMER & HANF, PC
3125 SPRINGBANK LANE
SUITE G
CHARLOTTE
NC
28226
US
|
Family ID: |
29549018 |
Appl. No.: |
11/938414 |
Filed: |
November 12, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10155253 |
May 24, 2002 |
7320845 |
|
|
11938414 |
Nov 12, 2007 |
|
|
|
Current U.S.
Class: |
429/124 ;
427/58 |
Current CPC
Class: |
H01M 6/40 20130101; H01M
10/0565 20130101; Y10T 29/49108 20150115; H01M 4/38 20130101; H01M
6/181 20130101; H01M 50/209 20210101; H01M 10/0436 20130101; H01M
4/50 20130101; Y02E 60/10 20130101 |
Class at
Publication: |
429/124 ;
427/058 |
International
Class: |
H01M 6/40 20060101
H01M006/40 |
Claims
1-14. (canceled)
15. A method of making a printed battery consisting essentially of
the following steps: printing a first conductive layer on a
flexible backing sheet; printing a first electrode layer on the
first conductive layer, where said first electrode layer is printed
with an ink having a base selected from the group consisting of
acrylics, alkyds, alginate, latex, polyurethane, linseed oil, and
hydrocarbon emulsions; printing an electrolyte layer on the first
electrode layer, said electrolyte layer comprises electrolyte salts
and a matrix material, said matrix material being selected from the
group consisting of aqueous acrylics, polyvinylidene fluoride
(PVDF), PVDF copolymers, polyacrylonitrile (PAN) and PAN
copolymers; printing a second electrode layer on said electrolyte
layer, where said second electrode layer is printed with an ink
having a base selected from the group consisting of acrylics,
alkyds, alginate, latex, polyurethane, linseed oil, and hydrocarbon
emulsions; and printing a second conductive layer on the second
electrode layer.
16. The method of claim 15 further consisting essentially of curing
each layer before printing a next layer.
17. The method of claim 16 where curing comprises drying.
18. The method of claim 17 where drying comprises the use of forced
hot air.
19. A printed battery comprising: a flexible backing sheet; a first
conductive layer printed on said sheet; a first electrode layer
printed on said first conductive layer, where said first electrode
layer is printed with an ink having a base selected from the group
consisting of acrylics, alkyds, alginate, latex, polyurethane,
linseed oil, and hydrocarbon emulsions; a separator layer printed
on said first electrode layer, said separator layer consisting
essentially of an electrolyte salt and a matrix material, said
matrix material being selected from the group consisting of a
highly filled aqueous acrylics, polyvinylidene fluoride (PVDF),
PVDF copolymers, polyacrylonitrile (PAN), and PAN copolymers, where
highly filled is defined by a filler content of at least 80%; a
second electrode layer printed on said separator layer, where said
second electrode layer is printed with an ink having a base
selected from the group consisting of acrylics, alkyds, alginate,
latex, polyurethane, linseed oil, and hydrocarbon emulsions; and a
second conductive layer printed on said second electrode layer.
20. The battery of claim 19 wherein said backing sheet being a
porous or nonporous material.
21. The battery of claim 20 wherein said sheet being selected from
the group consisting of paper and plastic sheets.
22. The battery of claim 21 wherein said plastic sheets being
selected from the group consisting of polyester, polyolefins,
polycarbonate, polyamide, polyimide, polyetherketone,
polyetheretherketone, polyethersulfone, polyphenylsulfide,
polystryene, polyvinyl chloride, and cellulose and its
derivatives.
23. The battery of claim 19 wherein printing being selected from
the group consisting of screen printing, pad printing, stenciling,
offset printing, and jet printing.
24. The battery of claim 19 wherein each conductive layer being
printed with an ink having a base selected from the group
consisting of acrylics, alkyds, alginate, latex, polyurethane,
linseed oil, and hydrocarbon emulsions.
25. The battery of claim 19 wherein one electrode being an anode
and one electrode being a cathode, said anode having an active
material selected from the group consisting of zinc, magnesium,
cadmium, and lithium, and said cathode having a material selected
from the group consisting of manganese dioxide, mercury oxide,
silver oxide, and other electro-active oxides.
23. A printed battery consisting essentially of: a flexible backing
sheet, where said flexible backing sheet being selected from the
group consisting of paper and plastic sheets; a first conductive
layer printed on said sheet, where said first conductive layer is
printed with an ink having a base selected from the group
consisting of acrylics, alkyds, alginate, latex, polyurethane,
linseed oil, and hydrocarbon emulsions; a first electrode layer
printed on said first conductive layer, where said first electrode
layer is printed with an ink having a base selected from the group
consisting of acrylics, alkyds, alginate, latex, polyurethane,
linseed oil, and hydrocarbon emulsions; an electrolyte layer
printed on said first electrode layer, said electrolyte layer
comprises electrolyte salts and a matrix material, said matrix
material being selected from the group consisting of highly filled
aqueous acrylics, polyvinylidene fluoride (PVDF), PVDF copolymers,
polyacrylonitrile (PAN) and PAN copolymers, where highly filled is
defined by a filler content of at least 80%; a second electrode
layer printed on said electrolyte layer, where said second
electrode layer is printed with an ink having a base selected from
the group consisting of acrylics, alkyds, alginate, latex,
polyurethane, linseed oil, and hydrocarbon emulsions; a second
conductive layer printed on said second electrode layer, where said
second conductive layer is printed with an ink having a base
selected from the group consisting of acrylics, alkyds, alginate,
latex, polyurethane, linseed oil, and hydrocarbon emulsions; and
where one electrode being an anode and one electrode being a
cathode, said anode having an active material selected from the
group consisting of zinc, magnesium, cadmium, and lithium, and said
cathode having a material selected from the group consisting of
manganese dioxide, mercury oxide, silver oxide.
24. The battery of claim 23 wherein said backing sheet is selected
from the group of a porous or nonporous material.
25. The battery of claim 23 wherein said plastic sheets being
selected from the group consisting of polyester, polyolefins,
polycarbonate, polyamide, polyimide, polyetherketone,
polyetheretherketone, polyethersulfone, polyphenylsulfide,
polystryene, polyvinyl chloride, and cellulose and its
derivatives.
26. The battery of claim 23 wherein printing being selected from
the group consisting of screen printing, pad printing, stenciling,
offset printing, and jet printing.
Description
FIELD OF THE INVENTION
[0001] This invention is directed to a thin, flexible battery in
which all active components are printed.
BACKGROUND OF THE INVENTION
[0002] Thin, flexible batteries, in which some but not all of the
components are printed, are known. For example, in U.S. Pat. No.
5,652,043, a thin flexible battery is made by printing some of the
components. This battery is not completely printed because it
requires a porous insoluble substance as part of its aqueous
electrolyte layer. That aqueous electrolyte layer comprises a
deliquescent material, an electro-active soluble material and
adhesive (or water soluble polymer) for binding the electrodes to
the electrolyte layer, and the porous insoluble substance. The
porous insoluble substance is described as filter paper, plastic
membrane, cellulose membrane, and cloth. The negative and positive
electrodes are then printed on either side of the electrolyte
layer. Conductive layers of graphite paper or carbon cloth may be
added over the electrolytes. Terminals, applied by printing, may be
included in the battery.
[0003] U.S. Pat. No. 5,019,467 discloses a flexible battery
comprising a flexible insulating material, a positive current
collection layer, a positive active layer, a solid polyelectrolyte
layer, and a thin metallic film layer as the anode. In this
battery, the positive current collection layer, positive active
layer, and solid polymer electrolyte layer are coated on the
flexible insulating material. The thin metallic layer is formed by
vacuum deposition, sputtering, ion-plating, or non-electrolytic
plating (i.e., not printed).
[0004] U.S. Pat. No. 5,747,191 discloses that polymer film inks may
be used to form a conductive layer (current collector) for a thin
flexible battery. This battery, however, requires an anode foil,
which is formed by "wave-soldering-like" method.
[0005] In U.S. Pat. No. 5,558,957, a thin flexible battery requires
the use of metal foils to form the current collectors, and anode
and cathode layers.
[0006] There is a need for a relatively inexpensive, thin, flexible
battery with a low energy density. Such a battery could be used in
transdermal delivery systems for pharmaceuticals to provide an
additional driving force to facilitate the diffusion of the drug
across the skin. Such a battery could be used in a skin sensor,
such as those used to monitor blood sugar levels or control insulin
pumps. These batteries could be used to power smart (transmitting)
baggage tags, ID's, and the like. Such a battery could also be used
to power certain novelty devices such as greeting cards.
[0007] Accordingly, there is a need for relatively inexpensive,
thin, flexible, disposable low energy density battery.
SUMMARY OF THE INVENTION
[0008] A printed battery comprising a flexible backing sheet, a
first conductive layer printed on said sheet; a first conductive
layer printed on the first conductive layer; a second electrode
layer printed on said first electrode layer; and a second
conductive layer printed on said second electrode layer.
[0009] A method of making a printed battery comprises the steps of:
printing a first conductive layer on a flexible backing sheet;
printing a first electrode layer on the first conductive layer;
printing a second electrode layer on the second conductive layer;
and printing a second conductive layer on the second electrode
layer.
DESCRIPTION OF THE DRAWINGS
[0010] For the purpose of illustrating the invention, there is
shown in the drawings a form that is presently preferred; it being
understood, however, that this invention is not limited to the
precise arrangements and instrumentalities shown.
[0011] FIG. 1 illustrates a first embodiment of the printed
battery.
[0012] FIG. 2 illustrates a second embodiment of the printed
battery.
DESCRIPTION OF THE INVENTION
[0013] Referring to the drawings, wherein like numerals indicate
like elements, there is shown in FIG. 1 a first embodiment of the
printed battery 10. Printed battery 10 includes a flexible
substrate 12. A first conductive layer 14 is printed on substrate
12. A first electrode layer 16 is then printed on first conductive
layer 14. A second electrode layer 18 is then printed on the first
electrode layer. Finally, a second conductive layer 20 is printed
on the second electrode layer 18.
[0014] In FIG. 2, a second embodiment of the printed battery 30 is
illustrated. Printed battery 30 is substantially the same as
printed battery 10 except that a separator/electrolyte layer 32 has
been printed between the first electrode layer 16 and the second
electrode layer 18.
[0015] In the printed battery, the current collectors or conductive
layers 14, 20, the first and second electrode layers 16, 18, and
the separator/electrolyte layer 32 are each printed onto the
flexible substrate 12. Printing is a process of transferring with
machinery an ink to a surface. Printing processes include
screen-printing, stenciling, pad printing, offset printing, jet
printing, block printing, engraved roll printing, flat
screen-printing, rotary screen-printing, and heat transfer type
printing.
[0016] Printing inks are a viscous to semi-solid suspension of
finely divided particles. The suspension may be in a drying oil or
a volatile solvent. The inks are dried in any conventional manner,
e.g., catalyzed, forced air or forced hot air. Drying oils include,
but are not limited to: linseed oil, alkyd, phenol-formaldehyde,
and other synthetic resins and hydrocarbon emulsions. Suitable inks
may have an acrylic base, an alkyd base, alginate base, latex base,
or polyurethane base. The acrylic based inks are preferred. In
these inks, the active material (finely divided particles discussed
below) and the ink base are mixed. For example, in the conductive
layers, an electrically conductive carbon and the ink base are
mixed. Preferably, the conductive carbon comprises at least 60% by
weight of the ink, and most preferably, at least 75%. Preferred
carbons have particle sizes less than or equal to 0.1 micron.
[0017] The battery chemistry used is not limited. Exemplary
chemistries include, but are not limited to: Leclanche (zinc-anode,
manganese dioxide-cathode), Magnesium (Mg-anode, MnO.sub.2-cathode)
Alkaline MnO.sub.2 (Zn-anode, MnO.sub.2-cathode), Mercury
(Zn-anode, HgO-cathode), Mercad (Cd-anode, Ag.sub.2O-cathode), and
Li/MnO.sub.2 (Li-anode, MnO.sub.2-cathode). Particles of the anode
material are mixed into the ink base. The anode active materials
are preferably selected from the group consisting of zinc,
magnesium, cadmium, and lithium. The anode particles comprise at
least 80% by weight of the ink; preferably, at least 90%; and most
preferred, at least 95%. The anode particle sizes are, preferably,
less than or equal to 0.5 micron. Particles of the cathode material
are mixed into the ink base. The cathode active materials are
preferably selected from the group consisting of manganese dioxide,
mercury oxide, silver oxide and other electro-active oxides. The
cathode particles comprise at least 80% by weight of the ink base;
preferably, at least 90%; and most preferred, at least 95%. The
cathode particle sizes are, preferably, less than or equal to 0.5
micron.
[0018] A separator may be interposed between the electrodes. The
separator is used to facilitate ion conduction between the anode
and the cathode and to separate the anode form the cathode. The
separator includes electrolyte salts and a matrix material. The
electrolyte salts are dictated by the choice of battery chemistry,
as is well known. The matrix material must not unduly hinder ion
conduction between the electrodes. The matrix material may be
porous or thinly printed. The matrix material include, for example,
highly filled aqueous acrylics, polyvinylidene fluoride (PVDF),
PVDF copolymers (e.g., PVDF:HFP), polyacrylonitrile (PAN), and PAN
copolymers. The preferred matrix material is the highly filled
aqueous acrylics (such as calcium sulfate or calcium carbonate),
which are inherently porous due to discontinuities in the polymer
coating/film upon drying. The filler preferably comprises at least
80% by weight of the layer. The filler preferably has particle
sizes less than or equal to 0.5 microns.
[0019] The flexible backing sheet may be any permeable or
impermeable substance and may be selected from the group consisting
of paper, polyester, polycarbonate, polyamide, polyimide,
polyetherketone, polyetheretherketone, polyethersulfone,
polyphenolynesulfide, polyolefins (e.g., polyethylene and
polypropylene), polystyrene, polyvinylidine chloride, and cellulose
and its derivatives.
[0020] The instant invention will be better understood with
reference to the following example.
EXAMPLE
[0021] A 2 cm.times.2 cm cell was printed using a 2 cm.times.2 cm
faced, smooth rubber pad into a sheet of standard office bond paper
and a sheet of polyester film (each having an approximate thickness
of about 0.07-0.08 mm). The impact of printing stock were
negligible on cell performance, but were noticeable on drying times
which were accelerated using forced hot air (e.g., from a hair
dryer). Three ink suspensions were prepared. First, a conductive
ink suspension was made. This suspension consisted of 79% weight of
conductive carbon (particle size <0.1.mu.) in an acrylic binder
(Rohm & Haas HA-8 acrylic binder). A positive electrode
(cathode) ink suspension was made. This suspension consisted of
96+% weight of manganese dioxide (particle size <0.4.mu.) in an
acrylic binder (Rohm & Haas HA-8 acrylic binder). A negative
electrode (anode) ink suspension was made. This suspension
consisted of 96+% weight of zinc powder (particle size <0.3.mu.)
in an acrylic binder (Rohm & Haas HA-8 acrylic binder). The
cell had an overall thickness (including the base sheet) of about
0.4 mm. The cell had a `no load` voltage of about 1.4 volts; a
continuous current density of about 0.09 mA/cm.sup.2 (the curve is
relatively linear and has a flat discharge curve); a capacity of
about 2-3 nAh/cm.sup.2; a maximum capacity (not sustainable for
over 2 milliseconds) of about 6 mA/cm.sup.2; an internal resistance
(at near discharge) of 3.75-5 ohms/cm.sup.2; and an internal
resistance (at outset, first 1 minute of use at 0.16 mA drain rate)
of 4 ohms.
[0022] The present invention may be embodied in other forms without
departing from the spirit and the essential attributes thereof,
and, accordingly, reference should be made to the appended claims,
rather than to the foregoing specification, as indicated the scope
of the invention.
* * * * *