Avery Dennison Corporation

Stephen E Billester

Frederick N Miekka

An ultra thin primary battery construction is disclosed along with a method for making same. The battery itself is a laminate construction consisting of a polymer film casing, printed thin film electrodes, and an aqueous electrolyte which is in intimate contact with the active surfaces of both electrodes. In this system, the electrodes themselves consist of a non-reactive conductive ink base having active electrode materials embedded into its surface. The anode to cathode electrode geometry may take one of many forms, however for ease of manufacturing, the anode and cathode electrodes face each other in an offset configuration that eliminates the need for a porous separator. The method of manufacture involves first forming the electrodes onto a polymer film followed by adding the appropriate aqueous electrolyte, and finally sealing the battery. The process for forming the electrodes themselves involves printing a polymer film with a layer of conductive ink, sprinkling an excess of active electrode material in powder form onto the wet surface of the freshly printed ink, drying or curing the ink, and finally removing any loose particles from the surface.

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Bothell, WA, United States of America

Stephen E Billester