Thin-Film Battery Packaging With Integrated Conductive Tabs
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Solution Overview
Problem
Conventional thin film battery packaging with protruding current collector tabs is prone to damage and leakage due to water vapor permeation, and existing solutions are not suitable for batteries with water vapor-sensitive materials.
Innovation Solution
A multilayer packaging structure with exposed portions of a metal layer that function as current collector tabs, eliminating the need for protruding connectors and enabling complete sealing against water vapor, where the metal layer is electrically conductive and connected to both the battery and external circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If protruding current collector tabs are used to deliver electric energy, then electrical connection is achieved, but the packaging structure becomes fragile and prone to breaking off during manufacturing and assembly
Solution Approach 1:
The patent merges the current collector tab function with the packaging structure itself by making the packaging structure electrically conductive. The packaging structure is formed with conductive material that serves both as the enclosure and as the electrical connection element, eliminating separate protruding tabs and their associated fragility issues.
Solution Approach 2:
The packaging structure is designed to perform multiple functions simultaneously: it provides mechanical enclosure, acts as a barrier to water vapor, and serves as the electrical conductor for current collection. This multi-functional design eliminates the need for separate tab components and their vulnerable protruding structures.
2Ease of operation
If protruding current collector tabs are used, then current can be delivered to external circuitry, but water vapor can permeate through the tab penetration points compromising battery reliability
Solution Approach 1:
The patent combines the electrical conduction function and the sealing function into a single integrated packaging structure. The conductive packaging material forms both the enclosure that seals against water vapor and the electrical pathway for current delivery, eliminating penetration points that would compromise the seal.
Solution Approach 2:
The packaging structure simultaneously provides three critical functions: mechanical enclosure, hermetic sealing against water vapor, and electrical conduction. This eliminates the need for separate tabs that would create vulnerability points in the sealing system.
3Ease of operation
If conventional packaging with tabs is used, then current collection is achieved, but the manufacturing process becomes complex requiring careful sealing phase attention to prevent water vapor permeation
Solution Approach 1:
The patent combines multiple functions into the packaging structure itself, eliminating the need for separate tab components and their associated assembly steps. The conductive packaging is formed as an integrated structure that requires no additional sealing operations at tab penetration points, simplifying the manufacturing process.
4Ease of operation
If protruding tabs are used for current delivery, then electrical connection is established, but the battery profile becomes non-uniform and tabs are easily damaged during assembly
Solution Approach 1:
The patent merges the electrical connection function into the flush packaging structure, eliminating protruding tabs. The conductive packaging extends to the same surface level as the rest of the battery enclosure, creating a uniform profile without external protrusions that would interfere with assembly or aesthetics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a redundant-free, sealed, and multipurpose packaging structure that acts as both a packaging and water vapor barrier, reducing the risk of tab breakage and ensuring uniform battery profiles, suitable for water vapor-sensitive materials.
Implementation Method 1
acts as both a packaging and water vapor barrier
Implementation Method 2
the metal layer is electrically conductive and connected to both the battery and external circuitry
Data Source
Figure 1~2b
Figure 3
Figure 4
AI summary
The present invention relates to multilayer packaging structure (10) for a thin film battery (5) wherein a metal layer (14) is sandwiched between a first layer (11) and a second layer (12). A first opening (21) is arranged in the first layer (11) such that a first portion (24) of the metal layer (14) associated with the first opening (21) is exposed and is configured to be able to be in electrical contact with a current collector of the thin film battery (5). A second opening (22) is arranged in the second layer (12) such that a second portion (25) of the metal layer (14) associated with the second opening (22) is exposed and is configured to be able to be electrically connected to an external circuitry. The invention further relates to a method (30) for manufacturing of the multilayer packaging structure (10).