Battery having multilayer protective casing
A battery comprises at least one battery cell on a support, the battery cell comprising (i) an electrolyte between a plurality of electrodes, and (ii) a top surface. A protective casing having a barrier layer contacts the top surface of the battery cell, the barrier layer comprising (i) an oxygen permeability or nitrogen permeability that is less than 80 cm 3 *mm/(m 2 *day), (ii) a carbon dioxide permeability that is less than 1 cm 3 *mm/(m 2 *day), and (iii) a water permeability that is less than 4 g*mm/(m 2 *day). A conformal coating covers the barrier layer, the conformal coating having a viscosity that is less than about 100,000 Pa-s at about 150° C. A cap is adhered to the conformal coating.
1. A battery comprising:
(a) at least one solid-state battery cell on a support, the battery cell comprising (i) an electrolyte between a plurality of electrodes, and (ii) a top surface;
(b) a barrier layer contacting the top surface of the battery cell, the barrier layer comprising poly(isobutylene) having (i) an oxygen permeability or nitrogen permeability that is less than 80 cm 3 *mm/(m 2 *day), (ii) a carbon dioxide permeability that is less than 1 cm 3 *mm/(m 2 *day), and (iii) a water permeability that is less than 4 g*mm/(M 2 *day);
(c) a conformal coating covering the barrier layer, the conformal coating comprising ethylene vinyl acetate, and having a viscosity that is less than about 100,000 Pa-s at about 150° C., and
(d) a cap adhered to the conformal coating.
2. A battery according to claim 1 wherein the barrier layer further comprises poly(vinyl chloride) or a mixture of poly(isobutylene) and poly(vinylidene chloride).
3. A battery according to claim 1 where the barrier layer comprises a thickness of less than 100 microns.
4. A battery according to claim 1 wherein the conformal coating comprises an elastic modulus of from about 0.05 GPa to about 2 GPa.
5. A battery according to claim 1 wherein the conformal coating comprises:
(i) a conformal layer having a viscosity that is less than about 100,000 Pa-s at 150° C.; and
(ii) a bonding layer covering the conformal layer, the bonding layer capable of adhering to the cap with peel strength greater than 30 N/m and a critical load that is greater than 10 N.
6. A battery according to claim 1 wherein the conformal coating comprises a layer of poly(isobutylene), poly(methyl methacrylate), polysiloxane or rubber.
7. A battery according to claim 1 wherein the cap comprises a plate of polymer, metal, ceramic or glass.
8. A battery according to claim 1 wherein the cap comprises mica, metal foil, polymer foil, metal foil coated with polymer, or metalized polymer film.
9. A battery comprising:
(a) at least one solid-state battery cell on a support, the battery cell comprising (i) an electrolyte between a plurality of electrodes, and (ii) a top surface;
(b) a barrier layer contacting the top surface of the battery cell, the barrier layer comprising poly(isobutylene) having (i) an oxygen permeability or nitrogen permeability that is less than 80 cm 3 *mm/(m 2 *day), (ii) a carbon dioxide permeability that is less than 1 cm 3 *mm/(m 2 *day), and (iii) a water permeability that is less than 4 g*mm/(m 2 *day);
(c) a conformal coating covering the barrier layer, the conformal coating (i) comprising ethylene vinyl acetate having a viscosity that is less than about 100,000 Pa-s at about 150° C., and (ii) adhering to a cap, the barrier layer, or both, with a peel strength of at least about 30 N/m and a critical load that is greater than 10 N; and
(d) the cap adhered to the conformal coating.
10. A battery according to claim 9 wherein the barrier layer further comprises poly(vinyl chloride) or a mixture of poly(isobutylene) and poly(vinylidene chloride).
11. A battery according to claim 9 wherein the conformal coating comprises an elastic modulus of from about 0.05 GPa to about 2 GPa.
12. A battery according to claim 10 wherein the conformal coating comprises a layer of poly(isobutylene), poly(methyl methacrylate), polysiloxane or rubber.
13. A battery according to claim 9 wherein the cap comprises a plate of polymer, metal, ceramic or glass.
14. A battery according to claim 9 wherein the cap comprises mica, metal foil, polymer foil, metal foil coated with polymer, or metalized polymer film.
15. A battery comprising:
(a) at least one solid-state battery cell on a support, the battery cell comprising (i) an electrolyte between a plurality of electrodes, and (ii) a top surface;
(b) a barrier layer contacting the top surface of the battery cell, the barrier layer comprising poly(isobutylene) having (i) an oxygen permeability or nitrogen permeability that is less than 80 cm 3 *mm*(m 2 *day), (ii) a carbon dioxide permeability that is less than 1 cm 3 -mm/m 2 -day, and (iii) a water permeability that is less than 4 g*mm/(m 2 *day);
(c) a conformal layer covering the barrier layer, the conformal layer comprising ethylene vinyl acetate having a viscosity that is less than about 100,000 Pa-s at about 150° C.;
(d) a bonding layer covering the conformal layer, the bonding layer capable of adhering to a cap with peel strength greater than 30 N/m and a first critical load greater than 10 N; and
(e) a cap adhered to the bonding layer.