High current thin electrochemical cell and methods of making the same
A battery including at least one electrochemical cell for generating an electrical current is provided, along with its method of manufacture. In one example, the electrochemical cell is provided on a first substrate and includes an anode and a plurality of cathodes. At least a portion of said anode is located between an adjacent two of said plurality of cathodes. In one example method of manufacture, the electrochemical cell is made via a printing press process.
1. A flexible battery including at least one electrochemical cell for generating an electrical current, said battery including:
a first substrate;
a second substrate;
a cathode collector layer provided on said first substrate;
a plurality of cathode layers provided on said cathode collector layer;
an electrically-neutral dielectric layer provided on said cathode collector layer between at least an adjacent two of the plurality of cathode layers;
an anode layer provided on said dielectric layer, said anode layer being electrically insulated from said cathode collector layer by said dielectric layer;
an electrolyte layer comprising a liquid electrolyte in contact with said plurality of cathode layers and said anode layer; and
wherein said first substrate is connected and sealed to said second substrate to form an inner space containing said electrolyte, and also containing at least a major portion of said plurality of cathode layers and at least a major portion of said anode layer within said inner space.
2. The battery of claim 1 , wherein the dielectric layer is located equidistant between said two adjacent cathode layers.
3. The battery of claim 2 , wherein the anode layer is located equidistant between said two adjacent cathode layers.
4. The battery of claim 1 , wherein the cathode collector layer includes a geometry having a length and a width such that the number of squares is generally 3 or less, wherein the number of squares is determined by dividing the cathode collector length by the cathode collector width.
5. The battery of claim 4 , wherein the length and width of the cathode collector geometry is such that the number of squares is generally 1, or approaching 1.
6. The battery of claim 1 , wherein only one of said plurality of cathode layers and said anode layer is comprised of a dried or cured ink, and wherein the other of said plurality of cathode layers and said anode layer is comprised of a strip of material.
7. The battery of claim 1 , further including a frame interposed between said first and second substrate to connect and seal said first substrate to said second substrate to form the inner space.
8. The battery of claim 1 , wherein said anode layer comprises dried or cured ink.
9. The battery of claim 8 , wherein said anode layer comprises printed zinc.
10. The battery of claim 1 , wherein said cathode layers and said anode layer all comprise dried or cured ink.
11. The battery of claim 1 , wherein said anode layer comprises a zinc foil applied over said cathode current collector via a pressure sensitive adhesive.
12. The battery of claim 1 , wherein said plurality of cathode layers are disposed in a co-planar arrangement.
13. The battery of claim 1 , wherein said dielectric layer is provided on said cathode collector layer between and co-planar with said adjacent two cathode layers.
14. The battery of claim 1 , wherein the cathode collector layer includes a non-rectilinear geometry having an effective length and an effective width such that the number of squares is generally 3 or less, wherein the number of squares is determined by dividing said effective length by the said effective width.