CN105027319A - 电池及制造电池的方法 - Google Patents
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Abstract
公开了纸电池,它包括在其上吸收有电解质材料的纤维素基板和设置在该纤维素基板的相对侧上的第一和第二阻隔基板。第一和第二阻隔基板各自具有印刷在其上的电极。第一和第二阻隔基板中的至少一个包括第一和第二聚合物层。此外,公开了制造纸电池的方法,包括在纤维素基板上吸收电解质材料和在该纤维素基板的相对侧上设置第一和第二阻隔基板的步骤。第一和第二阻隔基板各自具有印刷在其上的电极。第一和第二阻隔基板中的至少一个包括第一和第二聚合物层。
Description
相关申请的交叉引用
本申请要求2013年3月1日提交的美国临时申请序号61/771,207号的优先权,其内容经此引用全文并入本文。
技术领域
本发明通常涉及电池和制造电池的方法。
背景技术
“纸电池”作为薄电电池是本领域中已知的,它采用主要由纤维素形成的基板。纸电池较薄、有柔韧性且是环境友好的,这使它们能够集成到众多产品当中。纸电池的工作方式类似于常规化学电池,但区别在于纸电池是非腐蚀性的且不需要笨重的壳体。纸电池的示例性用途包括射频识别(RFID)设备、医疗诊断设备和药物递送透皮贴剂。
通过在纤维素基板上吸收电解质来制造纸电池。该电解质是吸湿性的,特别是当纸电池用在高温和/或高湿度应用中时。任何水进入纤维素基板都会导致电池性能的显著降低。为了帮助保护电池防止水分侵入,并保持电池的柔韧性,将薄塑料膜如具有铝涂层的聚对苯二甲酸乙二醇酯(PET)粘附到电池上作为外包装层和抵抗水分的“阻隔”层。PET/铝膜还用作基板,以使用导电性油墨在其上“印刷”电池电极。
纸电池目前在本领域中已知具有几个缺点。铝涂覆的PET膜阻隔层,其常常通过物理气相沉积(PVD)来沉积,并不能提供足够的水分阻隔,部分原因是由于允许水分从中穿过的“针眼”和划痕缺陷。另外,铝涂层具有电磁屏蔽效应,这在许多期望电磁传输的应用中是不利的,例如RFID器件。
因此,期望提供改进的纸电池和制造纸电池的方法,该纸电池具有提高的耐湿性且没有电磁屏蔽。此外,结合附图和本发明主题的这一背景,本发明主题的其它所期望的特征和特性可以从随后对本发明主题的详细描述和所附权利要求中显而易见地得出。
简要概述
在一个示例性实施方式中公开了纸电池,它包括在其上吸收有电解质材料的纤维素基板和设置在该纤维素基板的相对侧上的第一和第二阻隔基板。第一和第二阻隔基板各自具有印刷在其上的电极。第一和第二阻隔基板中的至少一个包括第一和第二聚合物层。
在另一个示例性实施方式中公开了制造纸电池的方法,包括在纤维素基板上吸收电解质材料和在该纤维素基板的相对侧上设置第一和第二阻隔基板的步骤。第一和第二阻隔基板各自具有印刷在其上的电极。第一和第二阻隔基板中的至少一个包括第一和第二聚合物层。
在又一示例性实施方式中公开了纸电池,它包括在其上吸收有电解质材料的纤维素基板,和设置在该纤维素基板的相对侧上的第一和第二阻隔基板,所述电解质材料包括氯化锌。第一和第二阻隔基板各自具有印刷在其上的电极。第一阻隔基板的电极包括锌,而第二阻隔基板的电极包括二氧化锰。第一和第二阻隔基板中的至少一个包括第一和第二聚合物层。第一聚合物层包括聚三氟氯乙烯,而第二聚合物层包括聚对苯二甲酸乙二醇酯。另外,第一和第二聚合物层层压或者共挤出在一起。
提供此简要概述是为了以简要的形式介绍所选的构思,在下文的具体描述中对它们作了进一步的描述。此概述无意于确定所要求保护的主题的关键特征或必要特征,也无意于用来帮助确定要求保护的主题的范围。
附图说明
下文将结合以下附图对本发明进行说明,其中相同的附图标记表示相同的元件,并且其中:
图1图解了本领域中目前已知的纸电池结构的截面。
图2图解了根据本发明的示例性实施方式的纸电池结构的截面。
具体描述
以下的具体描述本质上仅仅是示例性的,且无意于限制本发明或限制本发明的应用和用途。此外,无意于局限在前文的技术领域、背景技术、简要概述或下文的具体描述部分中提到的任何明示或暗示的理论。
本发明的实施方式广泛涉及纸电池和制造纸电池的方法。图1图解了本领域中目前已知的纸电池结构的截面。为了便于说明,其中所示的若干层101-106显示为彼此分开的(不相邻);但是可以理解,在实践中所述层101-106彼此粘附以形成整体的和功能性的电池。
图1所示的纸电池通常至少包括包含第一电化学层(例如阴极)的第一电极103,包含第二电化学层(例如阳极)的第二电极105,和布置在纤维素基板104上的电解质,它与电极相互作用产生电流。第一和第二电极(103,105)以及基板104上的电解质通常全部包含在两个或更多个阻隔基板102,106之间,所述阻隔基板提供了在其上“印刷”电极103,105的基板,还提供了电极与防止水分侵入电解质的防潮层之间的电绝缘。
对于第一和第二电极103,105,所述电极在相应的阻隔基板102,106上的沉积可以通过如下来实现,例如在一个或多个高速轮转印刷机上借助轮转丝网印刷站和/或柔性版印刷站来印刷导电性的和/或电化学的油墨和/或层压金属箔,如锌箔。其他适合的方法包括借助平板丝网印刷机或单张平板印刷机进行轮转印刷。适合用作阴极103的材料包括二氧化锰(MnO2)。适合用作阳极105的材料包括锌。可以用作阴极或阳极的其它配方在本领域中是已知的。
纤维素基板104可由源自木浆的纤维素纤维制备。纤维素纤维的例子包括但不限于源自木材如木浆的那些,以及源自棉花、源自稻草和禾草如水稻和细茎针草、源自藤条和芦苇如蔗渣、源自竹子、源自具有韧皮纤维的秸秆如黄麻、亚麻、洋麻、大麻、亚麻和苎麻、以及源自叶纤维如马尼拉麻和剑麻的非木质纤维。也可以使用一种或多种纤维素纤维的混合物。该纤维素基板104浸泡在电解质溶液中以在纤维素基板104上吸收电解质溶液。溶液中的氯化锌(ZnCl2)是示例性的电解质,并且可使用的浓度范围为例如约18重量%至45重量%。其它适合的电解质配方,诸如例如氯化铵(NH4Cl)、氯化锌(ZnCl2)与氯化铵(NH4Cl)的混合物、醋酸锌(Zn(C2H2O2))、溴化锌(ZnBr2)、氟化锌(ZnF2),酒石酸锌(ZnC4H4O6)、高氯酸锌Zn(ClO4)2)、氢氧化钾、氢氧化钠或有机物也可使用。
在其上印刷电极103,105的阻隔基板102,106可由塑料膜如聚丙烯塑料膜或聚乙烯塑料膜形成。为了改善阻隔基板102,106的水分阻隔性能,所述阻隔基板102,106中的一个或多个可设置为金属化膜。术语金属化膜指具有涂覆在其上的金属层的聚合物膜层。如图1所示,阻隔基板102包括设置在其上的金属层101。适合的金属化膜的例子包括金属化的聚对苯二甲酸乙二醇酯(MPET)和金属化的聚丙烯(MPP)。用作金属涂层101的示例性金属包括铝(Al)。
如前文所指出的,当采用金属化的阻隔基板时,在金属涂层中会产生允许水分从中穿过的“针眼”和划痕缺陷。此外,金属层101具有电磁屏蔽效应,这在期望电磁传输的应用中是不利的。因此,本发明的实施方式涉及改进的纸电池结构,它提供了比金属化塑料/聚合物膜涂层提高的耐湿性,且不存在如图1所示的目前本领域中已知的纸电池通常遇到的制造和传输屏蔽的缺点。
现在参考图2,其图解了根据本发明的示例性实施方式的纸电池结构的截面。如对图1所述,为了便于说明,其中所示的若干层201-206显示为彼此分开的(不相邻);但是可以理解,在实践中所述层201-206彼此粘附以形成整体的和功能性的电池。
如图2中所示,层203-206分别与上文针对图1描述的层103-106基本相同(也就是说,层203是第一电极如阴极,层204是在其上吸收有电解质的纤维素基板,层205是第二电极如阳极,且层206是聚合物阻隔基板)。本发明的实施方式是利用第一和第二聚合物层201、202,而不是采用金属化的塑料/聚合物层(例如图1的101,102)来用于防护水分侵入和用于在其上印刷第一电极的基板。在示例性的实施方式中,所述第二聚合物层202由PET形成,其如上所述提供水分阻隔保护,并且还充当在其上印刷电极的基板。第一聚合物层201由聚三氟氯乙烯(聚-CTFE或PCTFE)形成。在可选的实施方式中,第一聚合物层201由聚偏二氯乙烯(聚-VDC或PVDC)形成。在一个实施方式中,所述第一和第二聚合物层201、202可通过层压或共挤出成型到一起。在另一个实施方式中,层201可设置为可热封的PCTFE阻隔层以粘附到层202和/或206上。在又一个实施方式中,整个电池装置可通过PCTFE包封材料层(未示出)包封,由此层201可成形为连续环绕整个设备。在一个实施方式中,所述第一和第二聚合物层(层压或共挤出到一起)的厚度可从约25微米至约500微米,例如从约50微米至约300微米。
示例性的实施例
现在通过以下非限制性的实施例对本发明进行举例说明。应当指出,各种改变和变更可以应用到下面的实施例和方法中而不脱离本发明的范围,该范围在所附的权利要求中限定。因此,应指出的是,下面的实施例应当解释为只是说明性的,而不是在任何意义上的限制。
根据图2制备阻隔基板,利用PCTFE作为第一聚合物层,且PET作为第二聚合物层。第一和第二聚合物层层压在一起。层压后的第一和第二聚合物层的总厚度为约280微米。
如在SoftBattery®纸电池中使用的阻隔基板,其包括如图1的现有技术例子中的铝涂覆的PET基板阻隔层,商购自芬兰Vantaa的Enfucell Corporation用于比较的目的。此阻隔基板的测量显示铝涂覆的PET基板阻隔层的厚度为约50微米。
所制备的阻隔基板和对比的阻隔基板均暴露于40℃和75%相对湿度的气氛中。在所制备的阻隔基板中测得的水分侵入为0.50 g/m2/天。商购的对比阻隔基板中测得的水分侵入为5.50 g/m2/天。
由此,本发明的发明人意外地发现,借助第一和第二聚合物层(例如PCTFE和PET或PVDC和PET)作为阻隔基板代替金属化的塑料膜(例如铝涂覆的PET)制造的纸电池,提供了提高的对水分侵入的防护。另外,因为公开的纸电池不使用金属层或金属涂层,因此基本上避免了对电磁传输的阻挡。第一和第二聚合物层可以很容易地共挤出到一起或层压到一起,从而提供了简单和成本有效的制造方法。
虽然在前文对本发明主题的具体描述中已经给出了至少一个示例性实施方式,但应该理解存在数量众多的变型。还应当理解,这个或这些示例性的实施方式仅仅是例子,且无意于以任何方式限制本发明主题的范围、适用性或配置。相反,前文的具体描述为本领域技术人员提供了方便的路线图来实施本发明主题的示例性实施方式。可以理解,可以对示例性实施方式中描述的元件功能和布置进行各种改变而不脱离如在所附的权利要求中所限定的本发明主题的范围。
Claims (10)
1.一种纸电池,其包含:
在其上吸收有电解质材料的纤维素基板;和
设置在该纤维素基板的相对侧上的第一和第二阻隔基板,第一和第二阻隔基板各自具有印刷在其上的电极,
其中第一和第二阻隔基板中的至少一个包含第一和第二聚合物层。
2.根据权利要求1所述的纸电池,其中所述第一聚合物层包含聚三氟氯乙烯(PCTFE)。
3.根据权利要求2所述的纸电池,其中所述PCTFE包含可热封的PCTFE。
4.根据权利要求1所述的纸电池,其中所述第一聚合物层包含聚偏二氯乙烯。
5.根据权利要求1所述的纸电池,其中所述第二聚合物层包含聚对苯二甲酸乙二醇酯。
6.根据权利要求1所述的纸电池,其中所述电解质材料包含氯化锌。
7.根据权利要求1所述的纸电池,其中印刷的电极中的至少一个包含锌。
8.根据权利要求1所述的纸电池,其中印刷的电极中的至少一个包含二氧化锰。
9.根据权利要求1所述的纸电池,其中所述第一聚合物层包封所述纸电池。
10.根据权利要求9所述的纸电池,其中所述第二聚合物层包封所述纸电池。
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EP2962339A4 (en) | 2016-11-09 |
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