Abstract: A battery comprises at least one battery cell on a support, the battery cell comprising a plurality of electrodes about an electrolyte, and having a surface. A thermoplastic material covers the surface of the battery cell, the thermoplastic material comprising a nitrogen permeability or oxygen permeability that is less than 20 cm3*mm/(m2*day). A cap covers the thermoplastic material.

Abstract: A thin film battery manufacturing method is provided for deposition of lithium metal oxide films onto a battery substrate. The films are deposited in a sputtering chamber having a plurality of sputtering targets and magnetrons. The sputtering gas is energized by applying a voltage bias between a pair of the sputtering targets at a frequency of between about 10 and about 100 kHz. The method can provide a deposition rate of lithium cobalt oxide of between about 0.2 and about 4 microns/hr with improved film quality.

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 substrate having a surface, and a plurality of battery cells on the substrate surface. Each battery cell comprises an electrolyte having opposing surfaces, and a plurality of conductors in electrical contact with at least one of the opposing surfaces of the electrolyte, the plurality of conductors including a first conductor in electrical contact with a surface of the electrolyte and a second conductor in electrical contact with the opposing surface of the electrolyte. At least one electrical connector strip connects a conductor of a first battery cell to a conductor of a second battery cell to electrically couple the first and second battery cells to one another.

Abstract: A method of depositing lithium-containing films on a battery substrate in a sputtering chamber is provided. At least one pair of sputtering targets that each comprise a lithium-containing sputtering member is provided in the sputtering chamber, the sputtering targets selected to each have a conductivity of at least about 5×10?6 S·cm?1. A substrate carrier holding at least one battery substrate is placed in the sputtering chamber. A pressure of sputtering gas is maintained in the sputtering chamber. The sputtering gas is energized by applying to the pair of sputtering targets, an electrical power at a frequency of from about 10 to about 100 kHz.

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 battery packaging method comprises providing a battery comprising at least one battery cell on a substrate, the battery cell comprising a plurality of electrodes about an electrolyte, and the battery having at least one open peripheral side surface. A thermoplastic bead is provided at an open peripheral side surface of the battery. A cap is placed over the battery and in contact with the thermoplastic bead. The thermoplastic bead is locally heated by directing an energy beam onto the thermoplastic bead, the energy beam having a beam width sized sufficiently small to heat a beam incident region on the thermoplastic bead substantially without heating adjacent regions.

Abstract: A thin film battery comprises a substrate having a surface, and a plurality of battery cells on the substrate surface. Each battery cell comprises an electrolyte having opposing surfaces, and a plurality of conductors in electrical contact with at least one of the opposing surfaces of the electrolyte, the plurality of conductors including a first conductor in electrical contact with a surface of the electrolyte and a second conductor in electrical contact with the opposing surface of the electrolyte. At least one electrical connector strip connects a conductor of a first battery cell to a conductor of a second battery cell to electrically couple the first and second battery cells to one another.

Abstract: A battery comprises a substrate comprising a first surface comprising a first battery cell having a first non-contact surface, a pliable dielectric abutting the first non-contact surface, the pliable dielectric comprising a peripheral edge, and a first cap about the pliable dielectric.

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 battery fabrication method comprises forming at least one battery cell on a battery substrate by depositing a plurality of battery component films on the battery substrate, the battery component films comprising at least a pair of electrodes about an electrolyte. An overlying protective multilayer coating is formed over the battery cell. A plurality of pulsed laser bursts of a pulsed laser beam is applied to the battery substrate, the pulsed laser bursts having sufficient power and duration to cut through the battery substrate and the overlying protective multilayer coating.

Abstract: A battery comprises at least one battery cell on a support, the battery cell comprising a plurality of electrodes about an electrolyte, and having a surface. A thermoplastic material covers the surface of the battery cell, the thermoplastic material comprising a nitrogen permeability or oxygen permeability that is less than 20 cm3*mm/(m2*day). A cap covers the thermoplastic material.

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: In a method of fabricating a battery, a substrate is annealed to reduce surface contaminants or even water of crystallization from the substrate. A series of battery component films are deposited on a substrate, including an adhesion film, electrode films, and an electrolyte film. An adhesion film is deposited on the substrate and regions of the adhesion film are exposed to oxygen. An overlying stack of cathode films is deposited in successive deposition and annealing steps.

Abstract: A method of fabricating a battery comprises selecting a battery substrate having cleavage planes, and cutting the battery substrate with pulsed laser bursts from a pulsed laser beam to control or limit fracture along the cleavage planes. The pulsed laser beam was also found to work well on thin substrates which are sized less than 100 microns. Before or after the cutting step, a plurality of battery component films can be deposited on the battery substrate. The battery component films include at least a pair of electrodes about an electrolyte which cooperate to form a battery.

Abstract: A battery comprises a substrate comprising an electrolyte between a pair of conductors, at least one conductor having a non-contact surface. A cap is spaced apart from the non-contact surface of the conductor by a gap having a gap distance dg of from about 1 ?m to about 120 ?m. The gap allows the conductor to expand into the gap. The gap is further bounded by side faces about a surrounding perimeter that may be sealed with a seal. In one version, the ratio of the surface area of the non-contact surfaces on the conductor to the total surface area of the side faces is greater than about 10:1. A pliable dielectric can also be provided in the gap.

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 battery comprises a substrate comprising a first surface comprising a first battery cell having a first non-contact surface, a pliable dielectric abutting the first non-contact surface, the pliable dielectric comprising a peripheral edge, and a first cap about the pliable dielectric.

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 stacked battery comprises a first substrate having top and bottom surfaces, and a pair of spaced apart first holes that extend from the top surface to the bottom surface, each first hole having an edge. A first battery cell is on the first substrate, the first battery cell comprising at least a pair of electrode films with an electrolyte therebetween, and a pair of first contact pads, each contact pad contacting an electrode film and an edge of a first hole. A second battery cell is on a second substrate and has a pair of second contact pads that each contact an electrode film and an edge of a first hole. An electrical conductor in each first holes electrically connects a first contact pad to a second contact pad.