Abstract: A primary lithium battery, comprised of a battery package formed from a thin metal/polymer laminate and a single, elongated battery cell having a cathode section, an anode section and a separator disposed between the cathode section and the anode section. The cathode section includes a copper foil having a cathode film thereon. The cathode film includes manganese dioxide, carbon, a polymer binder and a plasticizer, the plasticizer consisting of propylene carbonate (PC). The anode section includes a copper foil having a lithium foil thereon. The battery is folded within the battery package and an electrolyte including propylene carbonate (PC), ethylene carbonate (EC) and a lithium salt are contained within the battery package.

Abstract: A package for a polymer battery, comprised of a generally rectangular sheet of a packaging laminate. The sheet of packaging laminate is comprised of a metallic foil layer disposed between two polymeric layers. A cavity is formed in the laminate at one end of the sheet. The cavity is generally rectangular in shape and has a bottom and four sides. The cavity is disposed in the sheet such that portions of the sheet define a flange that extends around at least three of the four sides of the cavity and a portion of the sheet defines a cover that is adapted to be folded over the cavity to overlay the flange. A protective/stiffening layer is disposed within the cavity along the four sides. The flange and the cover are hermetically sealed to each other.

Abstract: A method of forming battery leads, comprising the steps of: forming a plurality of aligned, spaced-apart elongated openings in a rectangular, metallic sheet, the metallic sheet having side edges and a width between the side edges equal to a desired length of a battery lead, the openings extending between the side edges and being aligned in a row that extends parallel to the side edges; treating areas of the surfaces of the metallic sheet between the openings to enhance the adhesive properties thereof; applying a strip of an adhesive/sealant material to each side of the metallic strip over the area and the slots; and cutting a battery lead from the metallic sheet by cutting the metallic sheet widthwise through each opening from one side edge to the other side edge.

Abstract: A method of connecting a generally flat battery lead to at least one flat current collector of a polymer battery, comprising the steps of: bending a generally planar lead about at least one generally planar current collector tab to form a layered area, wherein at least one planar tab is disposed between planar portions of the lead with the lead wrapped around one edge of at least one tab; clamping the layered area between two weld fixtures of an ultrasonic welder; and vibrating the weld fixtures to ultrasonically weld together the battery lead and at least one current collector tab.

Abstract: A Li-ion and/or Li-ion polymer battery, comprised of a plurality of battery cells, each battery cell comprised of at least one cathode section, an anode section and at least one separator layer disposed between the anode section and the at least one cathode section. A first, planar metal mesh layer is disposed within the anode section, the first metal mesh layer having a coplanar tab extending beyond the separator layer to define a negative lead. A second, planar metal mesh layer is disposed within the cathode section, the second metal mesh layer having a coplanar tab extending beyond the separator layer to form a positive lead. A plurality of reinforcing bands are wrapped around the peripheral edges of the battery cells securing the battery cells together.

Abstract: A separator for a Li-ion polymer battery comprised of a plurality of separator layers that are laminated together. The plurality of separator layers including a first layer formed of a first separator material, and a second layer formed of a second separator material, wherein the second layer is compositionally and structurally different from the first layer.

Abstract: A cathode slurry for use in a lithium battery, comprised of: about 60% to about 70% by weight manganese dioxide; about 5% to about 10% by weight carbon; and about 25% to about 35% by weight of an electrolyte, said electrolyte comprised of: about 10% to about 40% by weight ethylene carbonate, about 60% to about 90% by weight propylene carbonate, and about 0.5 to about 1.5 moles of triflate salt.

Abstract: A Li-ion and/or Li-ion polymer cell, comprised of a first cathode section and a second cathode section. Each cathode section has a cathode current collector in contact therewith. The cathode current collector is comprised of a sheet of metal mesh having a tab portion that extends outwardly from the sheet beyond the cathode section. The cathode tab from the first cathode section is disposed adjacent to the cathode tab from the second cathode section. An anode section is disposed between the cathode sections. The anode section has an anode current collector having a tab portion that extends therefrom beyond the anode section. A separator layer is disposed between the anode section and each of the cathode sections. A protective band is disposed between the tabs of each cathode current collector. The protective band is disposed between the cathode tabs and the anode section to prevent shorts when the cathode tabs are pressed together to form a single positive lead.

Abstract: A Li-ion or Li-ion polymer battery, comprised of a battery assembly having a plurality of generally planar cathode sections, each having a flat, metallic cathode current collector tab extending therefrom. A cathode tab weldment joins the cathode current collector tabs together with a cathode battery lead, and an anode tab weldment joins the anode current collector tabs together with an anode battery lead. A battery package contains the battery assembly with the anode tab weldment and the cathode tab weldment within the package and the anode and cathode battery leads extend through the package. A protective insert within the battery package surrounds the anode and cathode tab weldments and isolates the weldments from the battery package. The insert surrounds the battery leads where the battery leads extend through the package.

Abstract: A battery comprised of a generally rectangular electrochemical cell that has two battery leads attached to current collectors extending from one side thereof. A package formed from a sheet laminate has a cavity formed therein that defines an opening for receiving the cell and portions of the leads. A flange extends around the opening. A cover overlays the cavity and the flange. The cover is joined to the flange and forms a seal that hermetically seals the electrochemical cell within the cavity. The package has two, non-rectangular corners. The cover and the flange in the vicinity of the corners are shaped to allow the flange to be bent along the at least three sides in a manner wherein the flange is positioned adjacent the three sides, but the flange is not tucked or overlapped onto itself at the two, non-rectangular corners.

Abstract: A battery section for a Li-ion and/or Li-ion polymer cell, comprised of: a planar metal mesh layer having a body portion and a coplanar tab portion defining a battery lead extending from one edge of the mesh layer; electrode film laminated to opposite surfaces of the body portion of the metal mesh layer; and a protective layer on at least one side of the tab, the protective layer having a portion of the tab that is adjacent to the electrode film, the protective layer comprised of an outer polymer layer and an inner adhesive layer adhering the outer polymer layer to the portion of the tab.

Abstract: A multi-cell Li-ion or Li-ion polymer battery, comprised of a plurality of generally planar cell sections, each having at least one flat, metallic current collector tab extending therefrom. A plurality of the current collector tabs are aligned in spaced-apart relationship and extend from one side of the cell body. Each of the tabs has a free end and an intermediate portion. A tab weldment joins the free ends of the tabs but leaves the intermediate portions of the tabs unattached to each other. The tabs are welded together when the tabs are stacked together at a location offset from the cell body, such that the tabs are folded into a generally U-shaped configuration with the unattached intermediate portions forming a smooth layered, generally U-shaped structure when the tab weldment is disposed adjacent the one side of the cell body.

Abstract: A separator for a Li-ion polymer battery comprised of a plurality of separator layers that are laminated together. The plurality of separator layers including a first layer formed of a first separator material, and a second layer formed of a second separator material, wherein the second layer is compositionally and structurally different from the first layer.

Abstract: A Li-ion and/or Li-ion polymer cell, comprised of: a first cathode section and a second cathode section, each cathode section having a cathode current collector in contact therewith, the cathode current collector comprised of a sheet of metal mesh having a tab portion extending outwardly from the sheet beyond the cathode section to form a cathode section lead, the cathode section lead from the first cathode section being disposed adjacent to the cathode section lead from the second cathode section; an anode section disposed between the cathode sections, the anode section having an anode current collector having a tab portion extending therefrom beyond the anode section to form an anode section lead; a separator layer disposed between the anode section and each of the cathode sections; and an adhesive protective layer applied to the tab portion of each cathode current collector where the tab portion extends from the sheet, the protective layers disposed between the tab portions to prevent shorts when the tab

Abstract: A cathode slurry for use in a lithium battery, comprised of:

Abstract: A battery section for a Li-ion and/or Li-ion polymer cell, comprised of:

Abstract: An IC card comprising an electronic device and a battery within a plastic card for electrically energizing the electronic device. The battery is comprised of a monolithic electrochemical cell having a lithium-containing cathode, a carbon anode, and a porous polymer separator infused with electrolyte solution. The cell has a thickness of less than 0.7 mm. A package containing the cell formed of a sheet of flexible laminate material having at least one metal foil layer and a layer of an adhesive-like polymeric material. The battery has an overall thickness of less than 0.8 mm.

Abstract: A cathode slurry for use in a lithium battery, comprised of: about 60% to about 70% by weight electrolytic manganese dioxide; about 5% to about 10% by weight carbon; and about 25% to about 35% by weight of an electrolyte, said electrolyte comprised of: about 10% to about 40% by weight ethylene carbonate, about 60% to about 90% by weight propylene carbonate, and about 0.5 to about 1.5 moles of triflate salt.

Abstract: A method of forming a seal between a lead on a battery cell and flexible packaging enclosing the cell that comprises the steps of chemically cleaning at least a portion of a lead of a battery; roughening the surface of the portion of a lead to increase the surface area thereof; coating the entire periphery of the portion of a lead with a layer of a first polymeric material; the coating having a minimum thickness about equal to the thickness of the lead; positioning the portion of the lead between two flexible laminate sheets, the laminate sheets each having a layer of a second polymeric material, the laminate sheets being positioned to engage each other wherein the portion of the lead is disposed between the polymeric layers of the flexible laminate sheet; and applying sufficient heat and pressure to the flexible laminate sheets to soften the polymeric layers on the flexible laminate to cause the polymer layers to flow around and completely coat the layer of polymeric material on the lead.

Abstract: A flexible laminate for packaging a polymer electrolytic cell or battery, comprising: a first metallic foil layer; a second metallic foil layer; an intermediate separation layer disposed between the first and second metallic foil layers, the intermediate separation layer establishing a predetermined spacing between the first layer metallic foil and the second metallic foil layer; a first layer formed of a first self-sealing polymer on the first metallic foil layer.