Ceramic Via-Hole Cell Casing for Hermetic Miniature Batteries

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Solution Overview

Problem

Conventional sealing techniques are not practical for miniature electrochemical cells with volumes less than 0.5 cc, as seals take up a significant portion of the overall cell volume, and there is a need for materials that are chemically compatible and resistant to corrosion.

Innovation Solution

A casing construction using a ceramic container with a via hole filled with a metal-containing paste to form a conductive pathway, an anode current collector, and a hermetic seal with a conductive lid, allowing for a hermetic and electrically isolated miniature electrochemical cell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional sealing techniques are used in miniature electrochemical cells, then hermetic sealing is achieved, but the seal occupies a major portion of the overall cell volume

Engineering Contradiction:

Improvehermetic sealingVSAvoidcell volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The sealing function is merged with the cell casing structure itself. The ceramic container and conductive lid form an integrated hermetic seal without requiring separate seal components, thereby achieving reliable sealing while minimizing volume occupation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive lid serves multiple functions simultaneously: it provides hermetic sealing, establishes electrical connection through the conductive pathway, and forms part of the cell casing structure. This multi-functionality eliminates the need for dedicated seal components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Volume of moving object

If the cell size is reduced below 0.5 cc, then miniaturization is achieved, but conventional sealing techniques become impractical

Engineering Contradiction:

Improvecell volumeVSAvoidsealing practicality

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The ceramic container and conductive lid form a thin-walled yet hermetic structure suitable for miniaturization. The direct contact sealing interface between the lid and container eliminates the need for bulky seal components, making the design practical for sub-0.5 cc cells.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If materials are selected for chemical compatibility, then corrosion resistance is improved, but material selection becomes more restrictive

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmaterial selection flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The cell employs composite material construction with ceramic container, metallic conductive pathways, and selective metal plating (nickel, titanium, copper). This composite approach provides inherent corrosion resistance while maintaining electrical conductivity and chemical compatibility across different battery chemistries.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The nickel or titanium plating on the ceramic container serves as an intermediary layer between the conductive material and the battery electrolyte, providing corrosion resistance while allowing electrical conductivity. This mediator enables versatile material selection for different battery types.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 hermetic seal and electrical isolation in miniature cells, enabling reliable operation for over ten years while maintaining a compact size and preventing corrosion.

Implementation Method 1

The via hole is formed (drilled, punched or cut) with the ceramic container being in a green state. The open-ended ceramic container is then sintered to transform the metal-containing paste into a solid electrically conductive pathway extending through the sintered ceramic container.

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

An exemplary anode current collector according to the present invention is from about 0.1 microns to about 50 microns thick and is comprised of a metallic layer deposited on the inner surface of the ceramic container using a physical vapor deposition (PVD) process, for example sputtering deposition or evaporation deposition

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS12537135B2Miniature electrochemical cell having a casing of a conductive plate closing an open-ended ceramic container having a via hole supporting an electrically conductive pathway

Publication Date: 2026.01.27 GREATBATCH LTD

AI summary

A miniature electrochemical cell having a volume of less than 0.5 cc is described. The cell casing comprises an open-ended ceramic container having a via hole providing an electrically conductive pathway extending through the container. A metal lid closes the open-end of the container. An electrode assembly housed inside the casing comprises an anode current collector deposited on an inner surface of the ceramic container in contact with the electrically conductive pathway in the via hole. An anode active material contacts the current collector and a cathode active material contacts the metal lid. A separator is disposed between the anode and cathode active materials. That way, the electrically conductive pathway serves as a negative terminal, and the lid, electrically isolated from the conductive pathway by the ceramic container, serves as a positive terminal. The negative and positive terminals are configured for electrical connection to a load.