Sealed solid state battery

Patent metadata

Field	Value
Publication number	US-9793522-B2
Application number	US-201414503634-A
Country	US
Kind code	B2
Filing date	Oct 1, 2014
Priority date	Aug 13, 2014
Publication date	Oct 17, 2017
Grant date	Oct 17, 2017

Abstract

An electrochemical battery can include electrodes (a cathode and an electrode) arranged on respective surfaces of an electrolyte. The electrodes and electrolyte can each be solid state films that can be layered on top of one another to create a stacked structure disposed on a substrate. A polymeric sealant material can be applied over and around the battery stack and a moisture barrier can be formed over the sealant material to thereby prevent moisture from reaching the battery. Conductive terminals electrically coupled to the cathode and anode, respectively, can be formed on a second side of the substrate. As such, the battery can be flip-chip mounted to corresponding mounting pads and thereby connected to other electronics that can receive power from the battery.

First claim

What is claimed is:

1. A sealed battery comprising:
a substrate having a first side, a second side, and sidewalls;
a battery stack disposed on the first side of the substrate, wherein the battery stack comprises a cathode layer, an anode layer, and an electrolyte layer, wherein a first one of the cathode layer and the anode layer is disposed on the first side of the substrate, and wherein the electrolyte layer is disposed between the cathode layer and the anode layer;
a polymeric sealant layer formed over and around the battery stack and the substrate, wherein the polymeric sealant layer is substantially resistant to water swelling and extends along at least a portion of the sidewalls of the substrate;
a moisture barrier disposed around the polymeric sealant layer to thereby inhibit moisture from reaching the polymeric sealant layer and the battery stack,
wherein the moisture barrier is a continuous film that is substantially impervious to moisture,
wherein the moisture barrier adheres directly against the sidewalls of the substrate, and
wherein the moisture barrier entirely surrounds at least a portion of the battery stack and the polymeric sealant layer;
a first conductive pad situated on the second side of the substrate, wherein the first conductive pad is electrically coupled to the cathode layer; and
a second conductive pad situated on the second side of the substrate, wherein the second conductive pad is electrically coupled to the anode layer.

2. The sealed battery of claim 1 , wherein the polymeric sealant layer is a substantially continuous layer that fully encapsulates the battery stack between the polymeric sealant layer and the substrate.

3. The sealed battery of claim 1 , wherein the polymeric sealant layer becomes deformable above a temperature of between 100° C. and 200° C.

4. The sealed battery of claim 1 , wherein the moisture barrier is a metallic or ceramic coating.

5. The sealed battery of claim 1 , wherein the moisture barrier comprises:
a raised top region that is approximately parallel to the substrate; and
a transition region that trends toward the substrate from the raised top region.

6. The sealed battery of claim 1 ,
wherein an electrical path that couples the cathode layer and the first conductive pad includes a first via, wherein the first via comprises a first conductive material that at least partially occupies a first aperture through the substrate, and
wherein an electrical path that couples the anode layer and the second conductive pad includes a second via, wherein the second via comprises a second conductive material that at least partially occupies a second aperture through the substrate.

7. The sealed battery of claim 1 , wherein the cathode layer comprises a cathode active layer and a cathode current collector layer electrically coupled to the first conductive pad, wherein the cathode current collector layer comprises a first conductive material disposed on the first side of the substrate, and wherein the cathode active layer is disposed on the cathode current collector layer, and
wherein the anode layer comprises an anode active layer and an anode current collector layer electrically coupled to the second conductive pad, wherein the anode active layer comprises lithium metal disposed on the electrolyte layer, and wherein the anode current collector layer comprises a second conductive material disposed on the anode active layer.

8. The sealed battery of claim 1 , further comprising:
a secondary substrate;
a control chip disposed on the secondary substrate;
a bonding terminal disposed between the secondary substrate and the first conductive pad, wherein the bonding terminal is electrically coupled to the control chip via interconnects patterned on the secondary substrate; and
an anisotropic conductive adhesive material embedded with a first set of conductive particles disposed between the bonding terminal and the first conductive pad,
wherein the anisotropic conductive adhesive material comprises a second set of conductive particles distributed within an adhesive matrix, and
wherein at least one of the conductive particles provides electrical conductivity between the first conductive pad and the bonding terminal.

9. The sealed battery of claim 1 , wherein the moisture barrier adheres directly against the sidewalls of the substrate in a continuous ring.

10. The sealed battery of claim 1 , wherein the polymeric sealant layer is a biocompatible material.

11. The sealed battery of claim 10 , wherein the biocompatible material is parylene.

12. A body-mountable device comprising:
a polymeric material formed to have a body-mountable surface; and
a sealed battery embedded within the polymeric material, wherein the sealed battery comprises:
a substrate having a first side, a second side, and sidewalls;
a battery stack disposed on the first side of the substrate, wherein the battery stack comprises a cathode layer, an anode layer, and an electrolyte layer, wherein a first one of the cathode layer and the anode layer is disposed on the first side of the substrate, and wherein the electrolyte layer is disposed between the cathode layer and the anode layer;
a polymeric sealant layer formed over and around the battery stack and the substrate, wherein the polymeric sealant layer is substantially resistant to water swelling and extends along at least a portion of the sidewalls of the substrate;
a moisture barrier disposed around the polymeric sealant layer to thereby inhibit moisture from reaching the polymeric sealant layer and the battery stack,
wherein the moisture barrier is a continuous film that is substantially impervious to moisture,
wherein the moisture barrier adheres directly against the sidewalls of the substrate, and
wherein the moisture barrier entirely surrounds at least a portion of the battery stack and the polymeric sealant layer;
a first conductive pad situated on the second side of the substrate, wherein the first conductive pad is electrically coupled to the cathode layer; and
a second conductive pad situated on the second side of the substrate, wherein the second conductive pad is electrically coupled to the anode layer.

13. The body-mountable device of claim 12 , wherein the polymeric material has a concave surface and a convex surface, wherein the concave surface is configured to be removably mounted over a corneal surface and the convex surface is configured to be compatible with eyelid motion when the concave surface is so mounted.

14. The body-mountable device of claim 12 , wherein the body-mountable surface is tooth-mountable, and wherein the body-mountable device is configured to measure an analyte concentration of saliva.

15. The body-mountable device of claim 12 , wherein the polymeric sealant layer is a substantially continuous layer that fully encapsulates the battery stack between the polymeric sealant layer and the substrate.

16. The body-mountable device of claim 12 ,
wherein an electrical path that couples the cathode layer and the first conductive pad includes a first via, wherein the first via comprises a first conductive material that at least partially occupies a first aperture through the substrate, and
wherein an electrical path that couples the anode layer and the second conductive pad includes a second via, wherein the second via comprises a second conductive material that at least partially occupies a second aperture through the substrate.

17. The body-mountable device of claim 12 , further comprising electronics embedded in the polymeric material, wherein the electr

Assignees

• Verily Life Sciences Llc

Inventors

• Bhardwaj Ramesh C
• Etzkorn James
• Biederman William James
• Otis Brian

Classifications

• H01M10/0562 Primary

  Solid materials · CPC title

• G02C11/10

  Electronic devices other than hearing aids · CPC title

• H01M10/058 Primary

  Construction or manufacture · CPC title

• G02B1/043

  Contact lenses · CPC title

• H01M10/0585

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title