Abstract: Vertical via connections to a battery are hermetically sealed to prevent environmental factors (e.g. moisture, oxygen, and nitrogen) from entering the internals of the battery through porous conductive material filling the vias resulting in reduced battery performance and battery failure.

Abstract: Vertical via connections to a battery are hermetically sealed to prevent environmental factors (e.g. moisture, oxygen, and nitrogen) from entering the internals of the battery through porous conductive material filling the vias resulting in reduced battery performance and battery failure.

Abstract: A pulse mode apparatus comprises a mismatched battery electrically connected to a pulse mode device having a pulse duty cycle with a power-on time period and a power-off time period. The mismatched battery comprises a first battery cell having a first internal resistance and first charge capacity, and a second battery cell having a second internal resistance and second charge capacity, and the battery comprises at least one of the following: (1) the second internal resistance is less than the first internal resistance, and (2) the second charge capacity is less than the first charge capacity. The battery also has a pair of electrical connectors electrically coupling the first and second battery cells in parallel, a pair of terminals connected to the first or second battery cells, and a casing around the first and second battery cells with the terminals extending out of the casing.

Abstract: A lithium battery comprises at least one battery cell on a support, the battery cell comprising a plurality of electrodes about an electrolyte. A protective casing comprises a cover spaced apart from and covering the battery cell to form a gap therebetween with a polymer filling the gap. In one version, the polymer comprises polyvinylidene chloride polymer. First and second terminals extend out of the protective casing, the first and second terminals being connected to different electrodes of the battery cell.

Abstract: A lithium battery comprises a support, and a plurality of battery component layers on the support, the battery component layers including a cathode having a cathode area with a plurality of cathode perimeter edges. An electrolyte is on the cathode, and an anode is on the electrolyte. The anode comprises an anode area with a plurality of anode perimeter edges, each anode perimeter edge having a corresponding cathode perimeter edge that lies adjacent to and below the anode perimeter edge. The anode area is sized so that at least one anode perimeter edge is terminated before its corresponding cathode perimeter edge to define a gap between the anode perimeter edge and the corresponding cathode perimeter edge, the gap having a gap distance G.

Abstract: A pulse mode apparatus comprises a mismatched battery electrically connected to a pulse mode device having a pulse duty cycle with a power-on time period and a power-off time period. The mismatched battery comprises a first battery cell having a first internal resistance and first charge capacity, and a second battery cell having a second internal resistance and second charge capacity, and the battery comprises at least one of the following: (1) the second internal resistance is less than the first internal resistance, and (2) the second charge capacity is less than the first charge capacity. The battery also has a pair of electrical connectors electrically coupling the first and second battery cells in parallel, a pair of terminals connected to the first or second battery cells, and a casing around the first and second battery cells with the terminals extending out of the casing.

Abstract: A solid-state, mismatched battery comprises a first battery cell having a first internal resistance, and a second battery cell having a second internal resistance, the second internal resistance being a predefined resistance that is less than the first internal resistance. One or more of electrical connectors electrically couple the first and second battery cells. A casing encloses the first and second battery cells. A pair of terminals is electrically coupled to the first and second battery cells to output electrical power to an external load.

Abstract: A method of fabricating a battery comprises selecting a battery substrate having cleavage planes, and depositing at least one battery component film comprising a metal or metal compound. A plurality of pulsed laser beam bursts from a femtosecond laser source that is set to provide a pulsed laser beam having an irradiance level of from about 10 to about 800 J/cm2, are applied to the battery component film to vaporize at least a portion of the metal or metal compound of the battery component film substantially without causing fractures along the cleavage planes of the battery substrate.

Abstract: A method of fabricating a battery comprises selecting a battery substrate having cleavage planes, and depositing on the battery substrate, one or more battery component films comprising electrode films that at least partially surround an electrolyte film. Pulsed laser beam bursts are applied to the battery component films at a sufficiently high power level to vaporize portions of the films to form shaped battery features. The pulsed laser bursts shape the films substantially without causing fractures along the cleavage planes of the battery substrate. Pulsed laser shaping can be used to replace the use of a mask in the fabrication of shaped battery components.

Abstract: A lithium battery comprises a support, and a plurality of battery component layers on the support, the battery component layers including a cathode having a cathode area with a plurality of cathode perimeter edges. An electrolyte is on the cathode, and an anode is on the electrolyte. The anode comprises an anode area with a plurality of anode perimeter edges, each anode perimeter edge having a corresponding cathode perimeter edge that lies adjacent to and below the anode perimeter edge. The anode area is sized so that at least one anode perimeter edge is terminated before its corresponding cathode perimeter edge to define a gap between the anode perimeter edge and the corresponding cathode perimeter edge, the gap having a gap distance G.

Abstract: A solid-state, mismatched battery comprises a first battery cell having a first internal resistance, and a second battery cell having a second internal resistance, the second internal resistance being a predefined resistance that is less than the first internal resistance. One or more of electrical connectors electrically couple the first and second battery cells. A casing encloses the first and second battery cells. A pair of terminals is electrically coupled to the first and second battery cells to output electrical power to an external load.

Abstract: A method and apparatus for charging a rechargeable battery comprises determining a safe charging voltage Vsafe that is the maximum open circuit voltage of the battery which provides a minimum battery capacity for a predetermined number of charge and discharge cycles of the battery. The battery is charged with a voltage Vhv which is higher than the Vsafe. The charging voltage is removed and open circuit voltage of the battery is measured. The charging and measuring steps are repeated when the open circuit voltage is less than Vsafe, and the charging process is terminated when the open circuit voltage is substantially equal to Vsafe.

Abstract: A lithium battery comprises at least one battery cell on a support, the battery cell comprising a plurality of electrodes about an electrolyte. A protective casing comprises a cover spaced apart from and covering the battery cell to form a gap therebetween with a polymer filling the gap. In one version, the polymer comprises polyvinylidene chloride polymer. First and second terminals extend out of the protective casing, the first and second terminals being connected to different electrodes of the battery cell.

Abstract: A rechargeable battery comprises a battery cell comprising a plurality of battery component films on a substrate, the battery component films including at least a pair of electrodes about an electrolyte. A current limiter is electrically coupled to the battery cell to limit the current flowing through the battery cell when (i) the current flowing through the battery cell exceeds a predefined current, (ii) the temperature of the battery cell exceeds a predefined temperature, or (iii) both.

Abstract: A method and apparatus for charging a rechargeable battery comprises determining a safe charging voltage Vsafe that is the maximum open circuit voltage of the battery which provides a minimum battery capacity for a predetermined number of charge and discharge cycles of the battery. The battery is charged with a voltage Vhv which is higher than the Vsafe. The charging voltage is removed and open circuit voltage of the battery is measured. The charging and measuring steps are repeated when the open circuit voltage is less than Vsafe, and the charging process is terminated when the open circuit voltage is substantially equal to Vsafe.

Abstract: A thin film battery comprises a support with a battery cell. A cover covers the support and a sealant extends around the battery cell, and along the side perimeter surfaces between the support and cover. A protective shell covers at least one side perimeter surface. In one version, the protective shell includes alternating layers of polymer and diamond-like carbon. The protective shell increases the thin film battery cell's resistance to atmospheric and environmental degradation.

Abstract: A method of fabricating a battery comprises selecting a battery substrate having cleavage planes, and depositing on the battery substrate, one or more battery component films comprising electrode films that at least partially surround an electrolyte film. Pulsed laser beam bursts are applied to the battery component films at a sufficiently high power level to vaporize portions of the films to form shaped battery features. The pulsed laser bursts shape the films substantially without causing fractures along the cleavage planes of the battery substrate. Pulsed laser shaping can be used to replace the use of a mask in the fabrication of shaped battery components.