This invention is a method of fabricating a conformal
lithium polymer battery comprising the steps of: selecting a slab of
lithium polymer battery material of a desired height, containing a desired number of cells; freezing the slab; vertically
cutting the slab to a desired shape; attaching a lead to each
anode conductor; and attaching a lead to a each
cathode conductor. The slab may contain one or many cells. The leads may be made of multistranded, metallic wire, metallic ribbon,
low melting point alloy, self-healing
metal, and
litz wire. Attachment is accomplished so as to minimize tension on the leads. The
cut slab may need to be deburred after
cutting and before attaching leads. Preferably,
burr formation is prevented by recessing the edge of the anodic or cathodic half cells. Lead attachment my be accomplished by:
wire bonding;
wedge bonding;
adhesive bonding with conductive
epoxy, anistotropic conductive
adhesive or conductive
thermoplastic; stapling; adhering the lead to the
electrode by electropolymerization;
welding; and growing a lead in place by
electroless plating, electro-plating or a combination of
electroless plating and
electroplating. The distal ends of the leads may be connected together so that the cells are connected together in series, in parallel or some in series and the remainder in parallel. After the leads have been attached to the
cut slab and connected together, the
assembly will preferably be wrapped with standard packaging for
lithium polymer batteries.