RU2670597C1 - Bivalve batteries for biomedical device - Google Patents

Abstract

FIELD: electrical engineering.SUBSTANCE: invention relates to the field of electrical engineering, in particular to biocompatible bivalve batteries, in the manufacture of which sealed sealing layers are used, which reliably protect the chemical composition of the battery, increasing its biocompatibility, which allows the use of such a battery in a contact lens. Bivalve configuration essentially refers to forms with recesses and a protrusion along the edge, which can be joined together and sealed along the edge. Improving the tightness and reliability of the battery as part of a biomedical device is the technical result of the invention. Also a convenient and reliable method of forming a sealing layer for the formation of parts of a battery of a bicuspid configuration using different materials is proposed, including metals, ceramics, glass, semiconductor materials, etc., including changes in the conductivity of the material and the creation of contact areas.EFFECT: improving battery integrity can also be achieved through the use of plastic battery components.50 cl, 31 dwg, 1 tbl

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims advantage on provisional application for US patent No. 62 / 393,281, filed September 12, 2016.

BACKGROUND OF THE INVENTION

1. The scope of the invention

The present invention relates to electronic ophthalmic devices, such as wearable lenses, including contact lenses, implantable lenses, including intraocular lenses (IOL), as well as any other type of device containing optical components, and, more specifically, to configurations improving aspects of the biocompatibility of batteries, especially through the formation of bivalve configurations made of solid structures. In some other examples, the field of application of biocompatible batteries may include any biocompatible device or product for which batteries are required.

2. Description of the level of technology

As electronic devices continue to shrink in size, the creation of microelectronic devices suitable for wearing or made with the possibility of embedding for various applications becomes more and more likely. Such applications may include monitoring biochemical processes in the body, administering controlled doses of drugs or therapeutic agents through various mechanisms, including automatic, in response to measurements or in response to external control signals and enhancing functional processes in organs or tissues. Examples of such devices include glucose infusion pumps, pacemakers, defibrillators, ventricular auxiliary devices and neurostimulators. A new, especially used field of application are wearable ophthalmic lenses and contact lenses. For example, a lens assembly that has a focus with electronic adjustment to enhance or improve the function of the eye can be integrated into a wearable lens. In another example, electronic sensors for detecting concentrations of certain chemicals in the pre-corneal (tear) film can be embedded in a suitable contact lens with or without adjustable focus. The use of embedded electronic components in a lens assembly represents a potential need for communicating with electronic components, for providing power and / or reapplying power to electronic components, including power control or power management circuits, for interconnecting electronic components, for internal and external sensor and / or control devices, as well as to control the electronic components and the resulting function of the lens.

The human eye is capable of distinguishing millions of colors, it is easy to adapt to changing lighting conditions and transmit signals or information to the brain at a speed exceeding high-speed data transmission via the Internet. Currently, lenses, such as contact lenses and intraocular lenses, are used to correct visual defects such as myopia (myopia), hyperopia (long-sightedness), presbyopia, and astigmatism. However, correct configuration lenses with built-in add-on components can be used both to improve vision and correct vision defects.

Contact lenses can be used to correct myopia, hyperopia, astigmatism, and other visual acuity defects. Contact lenses can also be used to enhance the natural appearance of the user's lens. Contact lenses are simply lenses that are placed on the front of the eye. Contact lenses are medical devices and can be used for vision correction and / or for cosmetic or other therapeutic reasons. Contact lenses have been used for sales to improve vision since the 1950s. The first contact lenses were made or made of hard materials, were relatively expensive and fragile. In addition, these first contact lenses were made from materials that did not allow sufficient oxygen to penetrate the conjunctiva and the cornea through the contact lens, which could potentially lead to a number of adverse clinical effects. Although such contact lenses are currently used, they are not suitable for all patients due to the low level of initial comfort. Further developments in this area led to the creation of soft hydrogel-based contact lenses, which are extremely popular today and are widely used. In particular, silicone-hydrogel contact lenses currently available combine the advantages of silicone, which is characterized by exceptionally high oxygen permeability, with recognized wearing comfort and the clinical characteristics of hydrogels. As a rule, such silicone hydrogel contact lenses have a higher oxygen permeability, and, in essence, it is more convenient to wear them than contact lenses made from solid materials used in the past.

Standard contact lenses are polymeric structures with established forms for correcting various vision problems, which were briefly mentioned above. To achieve improved functionality, various schemes and components are embedded in these polymer structures. For example, control circuits, microprocessors, communication devices, power supplies, sensors, actuators, LEDs, and miniature antennas can be built into contact lenses through custom-made optoelectronic components designed not only to correct vision, but also to improve it and provide additional functionality as explained in this document. Electronic contact lenses and / or power contact lenses can be configured to improve vision by increasing or decreasing the focal length or simply changing the refractive properties of the lenses. Electronic power and contact lenses and / or power contact lenses can be configured to enhance color and resolution, display texture information, convert speech to subtitles in real time, transfer visual landmarks from the navigation system and provide image processing and Internet access. Lenses can be configured to allow the user to see in low light conditions. Properly designed electronic components and / or the arrangement of electronic components on the lenses may allow the image to be projected onto the retina, for example, without an optical lens with a variable focus, provide new image display devices, or even provide alerts for waking up. Alternatively, or in addition to any of these functions or similar functions, the components of non-invasive biomarker control and user health indicators may be embedded in contact lenses. For example, sensors built into the lenses may allow a diabetic patient to take tablets according to their blood sugar levels by analyzing the components of the tear film without the need for blood sampling. In addition, sensors can be integrated into a properly configured lens to monitor cholesterol, sodium, and potassium levels, as well as other biological markers. This, in combination with a wireless data transmitter, may allow the physician to have almost immediate access to the patient's biochemical blood test results without the patient having to spend time visiting the laboratory and conducting blood sampling. In addition, sensors embedded in lenses can be used to detect light falling on the eye, to compensate for external light conditions, or to use it in determining the nature of blinking.

The proper combination of devices can provide potentially unlimited functionality; However, there are a number of difficulties associated with the incorporation of additional components into a fragment of an optical-quality polymer. Essentially, obtaining such components directly on the lens, as well as mounting and interconnecting flat devices on a non-planar surface, are difficult for several reasons. It is also difficult to get them in scale. Components designed to be placed on or in the lens must be reduced in size and embedded in a transparent polymer measuring only 1.5 square centimeters, while protecting the components from the liquid medium of the eye. It is also difficult to manufacture a contact lens with an increased thickness, necessary to accommodate additional components, which would be comfortable and safe for the user.

Given the limitations on the area and volume of an ophthalmic device, such as a contact lens, and the environment in which it should be used, for its physical implementation it is necessary to overcome a number of problems, including the installation and interconnection of many electronic components on a non-planar surface, most of which consists of optical plastic. Thus, there is a need to create an electronic contact lens that will have a reliable configuration in terms of mechanics and electronics.

Since these lenses are electrically powered lenses, there is the problem of energy consumption or, more specifically, current that drives electronic components, taking into account battery technology on an ophthalmic lens scale. In addition to the usual current consumption, a device or system with this type of power supply generally requires idle current, precise voltage control and switching capabilities to operate in a potentially wide range of operating parameters, as well as peak consumption, for example, up to 18 (eighteen ) hours on one charge after a potential lack of activity for several years. Thus, there is a need for a power supply ophthalmic lens that is optimized for low-cost operation, long-term reliable service, safety, small size and speed, while providing the required power to control various components, including a variable-focus optical element.

One of the important components of such lenses are power supply elements that are used to power the lens and in many cases can be a battery. When using batteries in biomedical-type devices, it may be important that the structure and configuration of the battery takes into account aspects of biocompatibility. Thus, there is a need for new examples of manufacturing biocompatible batteries for use in biocompatible power supply cells that can significantly improve sealing aspects.

STATEMENT OF THE INVENTION

Accordingly, strategies and configurations for use in biocompatible batteries related to improved tightness have been disclosed. The bicuspid configuration essentially refers to molds with grooves and a protrusion along the edge that can be joined together and sealed along the edge. The protrusion can be made in the form of a thin element around the cavity or recess, which can be filled with other material. The thin element next to the battery material can be sealed in various ways and form a hermetic sealing layer. As already mentioned, hermetic sealing layers play an important role for the biocompatibility of the battery. Airtight sealing layers also play an important role for the functioning of the battery, since they can prevent the leakage of important battery components from it. In some cases, the importance of the sealing layer may be due to the need to prevent material from leaking out of the battery.

The bicuspid configuration can allow the processing of various materials to fill the configuration flaps with chemicals and battery components, and then to provide reliable and convenient ways to process the area of the sealing layer to form a good sealing layer. Various materials can be used to form parts of the bivalve configuration, including metals, ceramics, glass, semiconductor materials, and the like. Each type of material may have different advantages or characteristics associated with them, as discussed in this document. For example, impurities can be added to the semiconductor material to change the conductivity of the material and create contact areas.

In some examples, the sealing layers of various embodiments of the bicuspid configuration can be made even more hermetic by covering these layers and the bicuspid material with a metal seal, at least partially along the surface of the material. In some examples, the deposition by chemical reduction, which is used independently or with subsequent electrolytic deposition, can be used to form a metallic deposited layer on surfaces that may not be suitable for direct deposition by electrochemical methods. Improving the sealing layer and the integrity of the battery can, in particular, be achieved by the plastic components of the battery.

One general aspect includes a biomedical device that contains: an electroactive component and a battery. The battery also includes an anode current lead, in other cases, the anode serves as its own current lead. The battery also includes a cathode current lead. The battery also includes an anode. The battery also includes a cathode. The battery also includes a double-wing configuration encapsulating the anode and cathode with a first hole for the anode current lead, a second hole for the cathode current lead and a sealed sealing layer between the upper half of the double-wing configuration and the lower half of the double-wing configuration. The battery also includes a metal coating of at least part of the outer surface of the upper half of the bivalve configuration and the lower half of the bivalve configuration, and at least the first coating layer is applied to the metal coating by chemical reduction. The battery also includes a first biocompatible encapsulating layer, wherein the first biocompatible encapsulating layer encapsulates at least an electroactive component and a battery.

One general aspect includes a bivalve battery, which includes: an anode current lead, the anode current lead being the first metal film or foil on the upper half of the bivalve configuration; the anode, and the chemical composition of the anode is contained within the upper half of the bicuspid configuration or deposited on it; a cathode current lead, the cathode current lead being a second metal film or foil on the lower half of the bivalve configuration; the cathode, and the chemical composition of the cathode is contained within the lower half of the bivalve configuration or deposited on it; and where the upper half of the bivalve configuration and the lower half of the bivalve configuration are made of one or more ceramic, metal, glass or plastic materials, and where the sealing layer is formed between the projections of the upper half of the bivalve configuration and the lower half of the bivalve configuration.

One general aspect includes a double-leaf battery, which includes: an anode current lead, the anode current lead representing the first metal flap of a double-leaf configuration; the anode, and the chemical composition of the anode is contained within the first metal sash of a bicuspid configuration; the cathode current lead, and the cathode current lead is a second metal sash bivalve configuration; the cathode, and the chemical composition of the cathode is contained within the second metal sash of a bicuspid configuration; the insulating intermediate flap of the bicuspid configuration with the first sealing surface, which in a sealing manner interacts with the first metal flap of the bivalve configuration, and a second sealing surface, which in a sealing manner interacts with the second metal sash of the double configuration; and a sealing material that is placed in the gap between the first sealing surface and the first metal flap of the bivalve configuration.

One general aspect includes a bivalve battery, which includes: an anode current lead, the anode current lead being the first plastic flap of a bivalve configuration, and the plastic can be a conducting organic semiconductor; the anode, and the chemical composition of the anode is contained within the first plastic flap of a double-leaf configuration; the cathode current lead, and the cathode current lead is a second plastic flap of bivalve configuration; the cathode, and the chemical composition of the cathode is contained within the second plastic flap of the bicuspid configuration; and a sealing layer comprising a molten region, which includes protrusions of the first plastic flap of the bivalve configuration and the second plastic flap of the bivalve configuration. In some examples, the second flap of the double-leaf configuration may be a flat flap of a double-leaf battery.

One general aspect includes a bicuspid battery, which includes: an anode current lead, the anode current lead being the first semiconductor flap of a bivalve configuration; the anode, and the chemical composition of the anode is contained within the first semiconductor flap of a bivalve configuration; the cathode current lead, the cathode current lead being the second semiconductor leaf of the bivalve configuration; the cathode, and the chemical composition of the cathode is contained within the second semiconductor leaf of a bicuspid configuration; a sealing layer between the protrusions of the first semiconductor leaf of the bicuspid configuration and the second semiconductor leaf of the bicuspid configuration; and where in the isolated areas of the first semiconductor flap of the bivalve configuration and the second semiconductor leaf of the bivalve configuration, impurities are added to allow current to flow through the impurities from the battery to the external connection.

One general aspect includes a method of manufacturing a bivalve battery, which includes obtaining a first half of a bivalve configuration and a second half of a bivalve configuration made of an insulating material, wherein the half of a bivalve configuration includes a body portion for supporting the battery component around which the projection is located. In general, in the examples, a material protrusion may extend from the edge of the material of a body region, forming the edge of the flap. In some other examples, the protrusion may be a flat portion at the end of the material, forming the body of a bivalve configuration. In additional examples, one of the flaps forming the bivalve battery may comprise a body and a protrusion, and the second flap may be a flat flap, where the protrusion may be a theoretical element that surrounds or is adjacent to the peripheral part of the flat flap. The surfaces of the protrusions of the two flaps or the protrusion of the first flap and a portion of the second flat flap constitute surfaces that can be sealed around the whole body of the bivalve device.

The method also includes the formation of conductive paths in the first half of the bivalve configuration. The method also includes placing the anode in the first half of the bicuspid configuration. The method also includes placing the cathode in the second half of the bicuspid configuration. The method also includes placing a release film on one or both of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes applying electrolyte to one or both of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes joining the halves of the bicuspid configuration. The method also includes forming a sealing layer between the protrusions of the halves of the bivalve configuration.

One general aspect includes a method of manufacturing a bivalve battery, which includes obtaining a first half of a bivalve configuration and a second half of a bivalve configuration made of plastic material, wherein the half of a bivalve configuration includes a body portion to support a battery component around which a projection is located for sealing. The method also includes the formation of conductive paths in the first half of the bivalve configuration. The method also includes placing the anode in the first half of the bicuspid configuration. The method also includes placing the cathode in the second half of the bicuspid configuration. The method also includes placing a release film on one or both of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes applying electrolyte to one or both of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes joining the halves of the bicuspid configuration. The method also includes forming a sealing layer between the projections of the halves of the bivalve configuration, with the formation of the sealing layer comprising melting the plastic protrusions of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes sealing at least the surface areas of the first half of the bivalve configuration and the second half of the bivalve configuration by coating by chemical reduction.

One general aspect includes a method of manufacturing a bivalve battery, which includes obtaining a first half of a bivalve configuration made of a semiconductor material and a second half of a bivalve configuration made of a semiconductor material, with the half of a bivalve configuration including a housing portion to support the battery component around the protrusion, and the protrusion can be used for sealing. The method also includes the presence of areas with impurities on one or both of the first half of the bivalve configuration and the second half of the bivalve configuration, and the presence of impurities increases the conductivity of the material and creates a contact area. The method also includes applying a metal film to the surface of the first half of the bivalve configuration. The method also includes placing the anode in the first half of the bicuspid configuration. The method also includes placing the cathode in the second half of the bicuspid configuration. The method also includes placing a release film on one or both of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes applying electrolyte to one or both of the first half of the bivalve configuration and the second half of the bivalve configuration. The method also includes joining the halves of the bicuspid configuration. The method also includes forming a sealing layer between the protrusions of the halves of the bivalve configuration. The method also includes sealing at least the surface areas of the first half of the bivalve configuration and the second half of the bivalve configuration by coating by chemical reduction.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

The foregoing and other features and advantages of the present invention will become apparent after the following, more detailed description of the preferred embodiments of the invention shown in the accompanying drawings.

FIG. 1A-1B show exemplary aspects of power supply elements corresponding to examples of using contact lenses.

FIG. 2A1 shows an example of a cross section of a double configuration with the elements of the protrusions included.

FIG. 2A2 is an example of a cross section of a double configuration with prominent protrusion elements.

FIG. 2A3 shows an example of a cross-section of a double-wing configuration with a sash with a recess and a flat sash.

FIG. 2B-2E show aspects of examples of the double-leaf configuration with a hermetic sealing layer.

FIG. 3A-3I show further examples of bivalve battery configurations.

FIG. Figure 4 shows a bivalve configuration with more than two sealing components.

FIG. 5A-5D shows an example of a plastic bicuspid configuration in which the method of chemical reduction and electrolytic deposition is used to form a hermetic sealing layer.

FIG. 6A-6D show an example of a double-wing battery configuration.

FIG. 7 shows an example of the steps of a method of manufacturing a double-leaf battery with flaps made of an insulating material.

FIG. 8 shows an example of the steps of a method of manufacturing a double-leaf battery with flaps made of plastic material.

FIG. 9 shows an example of the steps of a method of manufacturing a double-leaf battery with flaps made of a metallic material.

FIG. 10 shows an example of the steps of a method for manufacturing a double-walled battery with flaps made of a semiconductor material.

DETAILED DESCRIPTION OF THE INVENTION

In this application describes the methods of manufacturing of bivalve batteries with improved biocompatibility. The following sections provide detailed descriptions of various examples. The descriptions of the examples are only exemplary embodiments, and various modifications and changes can be understood by those skilled in the art. Therefore, the examples do not limit the scope of this application. In some examples, these biocompatible batteries can be configured to be used inside or near the body of a living organism.

Definitions

In the description and the claims below, various terms may be used to which the definitions below apply.

As used herein, the term “anode” refers to an electrode through which an electric current flows into a polarized electrical device, such as a battery, during a discharge cycle. The direction of the electric current, as a rule, is opposite to the direction of the electron flow. In other words, electrons flow from the anode, for example, into an electrical circuit. In this document, a similar element of a polarized device refers to the anode, even if during the charge cycle and other events, such as electrolytic deposition of an element, standard definitions may denote this element differently.

In the context of this document, the term "battery" refers to an electrochemical power source, which consists of a single electrochemical cell or a plurality of electrochemical cells, appropriately connected to each other to provide the required voltage or current. Elements can be primary (non-rechargeable) or secondary (rechargeable) elements.

In this document, the term "binder" refers to a polymer that is capable of exhibiting elastic responses to mechanical deformations and which is chemically compatible with other components of the power supply element. For example, binders may include electroactive materials, electrolytes, polymers, etc. In some examples, the binder may refer to a substance that holds particles and / or particles + liquid together in an adhesive mass.

In this document, the term "biocompatible" refers to a material or device that functions in a particular application with an appropriate carrier response. For example, a biocompatible device does not cause toxic or traumatic effects on biological systems.

As used herein, the term “cathode” refers to an electrode through which an electrical current flows from a polarized electrical device, such as a battery, during a discharge cycle. The direction of the electric current, as a rule, is opposite to the direction of the electron flow. Therefore, the flow of electrons enters the cathode of a polarized electrical device and flows, for example, outside the connected electrical circuit. In this document, a similar element of a polarized device refers to a cathode, even if during the charge cycle and other events, such as electrolytic deposition of an element, standard definitions may denote this element differently.

In this document, the term “bivalve configuration” essentially refers to forms with recesses and a protrusion along the edge, which can be joined together and sealed along the edge. In some examples, the sash can be connected to each other. In other examples, the valves may exist as separate parts of the bivalve configuration. In some examples, the bivalve battery may be formed by a first flap that has a recess and a lip for sealing, while the second flap is a flat material that can be hermetically attached to the protrusion of the first flap.

In this document, the term "coating" refers to the application of thin layers of material. In some applications, this term will refer to a thin applied layer that essentially covers the surface of the substrate on which it is formed. In other more specialized applications, this term can be used to describe small, thin applied layers on smaller surface areas.

In this document, the term "electrode" can refer to the active mass in the energy source. For example, it may include one or both of the anode and cathode.

In this document, the term "with power" refers to the state of the ability to supply electrical current or store electrical energy inside.

In this document, the term "energy" refers to the ability of a physical system to perform work. Many applications of power supply elements may relate to the ability to perform electrical activities.

In this document, the term “energy source”, or “power supply unit I”, or “power supply unit” refers to any device or layer that is capable of supplying energy or translating a logical or electrical device into an electrically powered state. Power supply elements may include batteries. Batteries can be formed from alkaline-type chemical elements and can be solid-state batteries or liquid-element batteries, including an aqueous alkali, aqueous acid or water salt or non-aqueous components, a molten salt component or a solid-state component as an electrolyte component. Batteries can be a dry cell (immobilized electrolyte) or a liquid cell (free, liquid electrolyte).

In this document, the term "fillers" refers to one or more separators of power supply elements that do not interact with either acidic or alkaline electrolytes. Essentially fillers may include essentially water-insoluble materials, such as carbon black; coal dust; graphite; metal oxides and hydroxides, such as silicon, aluminum, calcium, magnesium, barium, titanium, iron, zinc, and tin; metal carbonates, such as calcium and magnesium; minerals such as mica, montmorillonite, kaolinite, attapulgite and talc; synthetic and natural zeolites, such as Portland cement; precipitated metal silicates, for example calcium silicate; hollow or solid polymer or glass microspheres, plates and fibers; etc.

In this document, the term "functionalized" refers to the implementation of a layer or device capable of performing a certain function, including, for example, power supply, activation, and / or control.

In this document, the term "casting mold" refers to a rigid or semi-rigid object that can be used to form three-dimensional objects from unpolymerized compositions. Some examples of molds for casting include two parts of the mold for casting, which when combined with each other form the construction of a three-dimensional object.

In this document, the term "power" refers to work performed or energy transmitted per unit of time.

In this document, the terms "rechargeable" or "re-plug-in power" refer to the ability to recover to a state with a higher ability to perform work. In many cases, these terms may refer to recoverability with the ability to provide an electrical current of a certain magnitude for certain periodically repeating periods of time.

In this document, the terms “recharge” or “reconnect to power” refer to restoring to a state of increased ability to perform work. In many cases, these terms may refer to the possibility of restoring a device to the ability to provide an electric current of a certain magnitude for certain periodically repeating periods of time.

In this document, the term “released”, or sometimes “released from the casting mold,” means that a three-dimensional object is either completely separated from the casting mold or only loosely attached to the casting mold, so that it can be removed by shaking it.

The term “multi-layered” as used herein refers to placing at least two layers of components close to each other in such a way that at least a portion of one surface of one of the layers contacts the first surface of the second layer. In some examples, between the two layers may be a coating that provides adhesion or other functions, so that the layers are in contact with each other through the specified coating.

In this document, the term "track" refers to the components of the power supply, made with the possibility of connecting together the components of the circuit. For example, chain lanes can include copper or gold if the substrate is a printed circuit board, and, as a rule, can be a film of copper or gold, a printed film in a flexible circuit. The current lead is a “track” of a special type. The current leads are electrochemical compatible paths that allow the use of current leads to transfer electrons to and from the anode or cathode of the electrochemical cell.

There may be other examples of methods for assembling and manufacturing batteries in accordance with the present description, and some of them can be described in the following sections. However, for many of these examples, there are selected battery parameters and characteristics that can be described separately. The following sections will focus on some of the features and parameters.

An example of the design of a biomedical device with biocompatible elements of energy supply

An example of a biomedical device into which the power supply elements (batteries) of the present invention can be embedded may be an electroactive contact lens with a variable focus. FIG. 1A shows an insert 100 for a contact lens as an example of an insert for such a contact lens. In the insert 100 for a contact lens may be an electroactive element 120, which may change the focal characteristics in response to voltage control signals. Circuit 105 may provide power from biocompatible battery cell 110 to provide these voltage control signals as well as to provide other functions, such as a sensor monitoring environmental conditions for external control signals. As shown in FIG. 1A, a battery cell 110 may consist of a plurality of large parts, in this case three parts, and may include chemical battery cells of various configurations, as described above. The battery cells 110 may have various connecting members for joining parts together, as shown in the figure below the connection region 114. The battery cells 110 may be connected to circuit element 105, which may have its own backing 115, on which the connecting members 125 can and 130. The circuit 105, which may be in the form of an integrated circuit, may be electrically and physically connected to the substrate 115 and its connecting elements 125 and 130.

FIG. 1B shows that the cross-sectional relief of the contact lens 150 may comprise an insert 100 for the contact lens and its components described above. The contact lens insert 100 can be sealed in a skirt of a hydrogel 155 contact lens, which can seal the contact lens insert 100 and ensure a comfortable interaction of the contact lens 150 with the user's eye.

Microbattery Power Requirements

Another area of design considerations may relate to the power requirements of the device, which may be provided by a battery. In order to function as a power source for a medical device, a suitable battery may need to be fully met with the power requirements of the system when operating autonomously or without external power sources. The developing field of biomedical devices, operating autonomously or without external power sources, may include, for example, contact lenses for vision correction, health monitoring devices, tablet cameras and other new devices. Recent developments in integrated circuit technology (IC) can allow electrical devices to be operated at very low current levels, for example, at the picoamper level for no-load current and at the microamp level for the operating current. ICs can also significantly reduce the size of devices.

Microbatteries for biomedical applications may need to simultaneously meet a number of complex requirements. For example, microbatteries may be required to provide an acceptable operating voltage for embedded electrical circuits. This operating voltage may depend on several factors, including the functional “node” of the IC, the output voltage signal from the circuit to another device, as well as the specific target indicator for current consumption, which can also relate to the estimated service life of the device.

From the point of view of the IP function, the nodes, as a rule, can differ in the minimum size of a transistor element, such as the so-called “transistor channel”. This physical element, along with other IP production parameters, such as the thickness of the gate oxide layer, can be related to the obtained nominal threshold voltage, or field-effect transistor (FET), produced for a particular functional unit. For example, in a node with a minimum element size of 0.5 microns, as a rule, FETs with an on voltage of 5.0 V. are used. Manufacturers of ICs can supply standard galvanic elements of digital units, such as inverters and triggers with characteristics that correspond to specific voltage ranges. Designers choose an IC functional unit based on a number of factors, including the density of digital devices, the ability to combine analog and digital circuits, leakage current, the number of layers of connections, and the availability of special devices, such as high-voltage field-effect transistors. Given these parametric aspects of electrical components that can receive power from a microbattery, it may be important to ensure that the microbattery power supply meets the requirements of the selected functional unit and the IC configuration, especially in terms of the available voltage and current levels.

In some examples, an electrical circuit that receives power from a microbattery can be connected to another device. As a non-limiting example, an electrical circuit that receives power from a microbattery can be connected to an actuator or converter. Depending on the application, it can be an LED (LED), a sensor, a pump based on microelectromechanical systems (MEMS) and many other similar devices. In some examples, devices connected in this manner may require a higher operating voltage than standard functional ICs. For example, a variable focus lens may require a voltage of 35 V. Consequently, the operating voltage provided by the battery may be a critical factor when designing such a system. In some examples related to such factors, the efficiency of a lens drive converting a battery voltage of 1 V to a voltage of 35 V may be significantly lower than the efficiency of a drive operating on a battery of 2 V. Additional requirements, such as crystal size, may vary significantly including taking into account the operating parameters of the microbattery.

Separate galvanic cells of the battery, as a rule, can be characterized by open circuit voltage, load voltage and cutoff voltage. An open circuit voltage is the potential created by a galvanic cell battery with infinite load resistance. Voltage with a load is the potential created by a galvanic cell when a load is connected to the terminals of a galvanic cell with a corresponding and, as a rule, also established value of impedance. The cut-off voltage is usually the voltage at which most of the battery is discharged. The cut-off voltage can be a voltage, or the degree of discharge, below which the battery cannot be discharged in order to avoid undesirable consequences, such as a strong release of gases. The cut-off voltage may depend, as a rule, not on the battery itself, but on the circuit to which the battery is connected, for example, on the operating voltage of the electronic circuit. In one example, an alkaline galvanic cell can have a voltage at an open circuit of 1.6 V, a voltage with a load in the range from 1.0 to 1.5 V, and a cut-off voltage of 1.0 V. and on other characteristics of the used chemical composition of the galvanic cell. And therefore different in chemical composition galvanic cells may have different indicators of the voltage of the element.

To increase the voltage, the galvanic cells can be connected in series; However, this combination may entail an increase in size, increase in internal resistance and complication of the battery. Galvanic cells can also be combined in parallel configurations to reduce resistance and increase capacity; However, this combination may entail an increase in battery size and a reduction in shelf life.

The capacity of the battery may be the ability of the battery to produce current or perform work for a certain period of time. The capacity of a battery can, as a rule, be specified in units such as microamper-hours. The battery, which can provide 1 microampere current for 1 hour, has a capacity of 1 microamper hour. Typically, the battery capacity can be increased by increasing the mass (and, therefore, volume) of the reagents inside the battery device; however, it should be borne in mind that biomedical devices may be significantly limited in terms of available volume. The battery capacity can also be affected by the material of the electrode and the electrolyte, as well as other factors, such as the physical design of the electrodes, the properties and dimensions of the material of any separator located between the electrodes, and the relative proportions of the anode, cathode active materials, electrically conductive materials and electrolyte.

Depending on the requirements of the circuit to which the battery is connected, the battery may be required to serve as a source of current for a certain range of values. During storage prior to active use, leakage current can flow through the circuits, connections, and insulators, in the order of magnitude from several picoampers to several nanoampers. During the period of active operation, the circuit can consume a quiescent current to read the sensor readings, start timers, and perform other similar functions with low power consumption. Quiescent current consumption can be on the order of a few nanoampere to a few milliamperes. A circuit can also have even greater needs for peak current, for example, when writing data to an electrically programmable read-only memory or when transmitting it at a radio frequency (RF). This peak current can be up to tens of milliamperes or more. The resistance and impedance of the microbattery may also be important for configuration aspects.

The shelf life generally refers to the period of time during which the battery can maintain suitable operating parameters. The shelf life may be particularly important for biomedical devices for several reasons. Electronic devices can replace non-powered devices, for example, when electronic contact lenses are introduced. Products in these existing market segments may have established requirements for shelf life, for example, three years, based on the wishes of consumers, characteristics of the supply chain and other requirements. As a rule, changing such specifications for new products is considered undesirable. Requirements for shelf life can also be set taking into account distribution factors, inventory and how to use the device, which includes a microbattery. Accordingly, microbatteries for biomedical devices may have specific shelf life requirements that can be measured, for example, by number of years.

In some examples, the three-dimensional biocompatible power supply elements may be rechargeable. For example, an induction coil may also be made on a three-dimensional surface. Subsequently, the induction coil can receive power supply using a radio frequency (RF) pulse. The induction coil can be connected to a three-dimensional biocompatible power supply element to recharge the power supply element when the RF is applied to the induction coil. In another example, photovoltaic devices can also be fabricated on a three-dimensional surface and connected to a three-dimensional biocompatible power supply element. Under the action of light or photons, photovoltaic devices will produce electrons to recharge the power supply element.

In some examples, batteries may operate to provide electrical energy to an electrical system. In these examples, the battery may be electrically connected to an electrical system circuit. Connections between the circuit and the battery can be classified as connections. These compounds may, over time, present a problem for biomedical microbatars due to several factors. In some examples, biomedical powering devices can be very small, thus providing small areas and volumes for connections. Restrictions on size and area can adversely affect the magnitude of the electrical resistance and the reliability of the connections.

In addition, the battery may contain liquid electrolyte, which may boil at high temperatures. This limitation can directly compete with the desire to use a solder joint that can melt, for example, at relatively high temperatures, such as 250 degrees Celsius. Although in some examples the chemical components of the battery, including the electrolyte, and the heat source used to form the solder joints, can be spatially separated from each other. In the case of promising biomedical devices, small size may prevent electrolyte and solder joints from being separated by a distance sufficient to reduce conductivity.

Modular Battery Components

In some examples, it is possible to manufacture a component of a modular battery in accordance with certain aspects and examples of the present invention. In these examples, the modular battery assembly may be a component separate from other parts of the biomedical device. In an example of an ophthalmic contact lens device, such a configuration may include a modular battery that is separate from the rest of the substrate insert. There are many advantages to forming a modular battery component. For example, in the example of a contact lens, a component of a modular battery can be formed in a separate, independent process, which can alleviate the need for manipulation of rigid three-dimensional optical plastic components. In addition, manufacturing tools can be more flexible and can perform operations in parallel with the manufacture of other components of the biomedical device. In addition, the manufacture of components of a modular battery can be separated from the characteristics of three-dimensional (3D) shape devices. For example, in applications requiring final three-dimensional shapes, a modular battery system can be manufactured in a flat or approximately two-dimensional (2D) form, and subsequently be given a corresponding three-dimensional shape. In some examples, the battery may have a sufficiently small size in order not to disturb the three-dimensional shape, even if it is not bent. In some other examples, a plurality of connected small batteries may be installed in a three-dimensional space. The component of the modular battery can be tested independently of the rest of the biomedical device, and loss of output due to battery components can be discarded prior to assembly. The resulting component of the modular battery can be used in various designs of the liner-substrate, which do not have a corresponding rigid area on which to place the components of the battery; In yet another additional example, the use of modular battery components may facilitate the use of variants of manufacturing techniques other than those that might otherwise be used, such as roll-to-roll (sheet-to-sheet) technology, printing, lithography and doctor printing. In some examples of a modular battery, the discrete leakage aspect of such a device may lead to the addition of additional material to the overall design of the biomedical device. Such effects can set a limit on the use of solutions in the form of modular batteries in cases where the parameters of the available space require minimizing the thickness or volume of solutions.

Internal sealing layers of the battery cell

In some examples of battery cells for use in biomedical devices, the chemical action of a battery includes an aqueous chemical composition, where water or moisture is an important component for control. Therefore, it may be important to embed sealing mechanisms that limit or prevent the movement of moisture either outside or inside the body of the battery. Means of protection against moisture can be made with the ability to maintain the level of internal humidity at the calculated level within the tolerances. In some examples, moisture protection agents can be divided into two sections or two components, namely, an insulating sheath and a sealing layer.

Hermetic casing can be considered the main material of the body. In some examples, the insulating sheath may contain bulk material. Water vapor penetration rate (WVTR) can be an indicator of performance, with ISO and / or ASTM standards monitoring the test procedure, including environmental conditions during the test. Ideally, the WVTR for a good insulating battery shell may be zero. Examples of materials with almost zero WVTR can be glass and metal foil, as well as ceramic and metal elements. Plastic, on the other hand, can be essentially porous and leaky, which can vary considerably between different types of plastic. As a rule, structural materials, laminates or coextrudates can be hybrids of conventional insulating shell materials.

The sealing layer can serve as a partition between the two surfaces of the insulating sheath. Joining the surfaces of the sealing layer completes the creation of the body along with the insulating sheath. In many examples, the nature of the configurations of the sealing layer may make it difficult to evaluate them for the WVTR sealing layer due to the difficulty of making measurements using ISO or ASTM, since the sample volume or surface area may not be compatible with these procedures. In some examples, a practical way to test the integrity of the sealing layer may be a functional test of the actual configuration of the sealing layer for some specific conditions. The effectiveness of the seal may depend on the material of the sealing layer, the thickness of the sealing layer, the length of the sealing layer and the width of the sealing layer, as well as the adhesion or proximity of the sealing layer to the substrates of the insulating sheath.

In some examples, sealing layers may be formed using a welding method, which may include thermal, laser, friction, ultrasonic, or arc welding, as well as solvent welding. In other examples, sealing layers may be formed by applying adhesive sealants such as adhesives, epoxy and acrylic compounds, natural rubber, synthetic rubber, resins, tar or bitumen. Other examples may be associated with the use of sealing materials, which can be made of natural and synthetic rubber, polytetrafluoroethylene (PTFE), polypropylene, or silicones, which are only a few non-restrictive examples. In some examples, the sealing material may be thermosetting, thermoplastic, or a combination of thermosetting and thermoplastic materials.

In some examples, batteries in accordance with the present disclosure may be configured to have a specified useful life. The useful life can be estimated by practical determination of the amount of moisture permeability that can be obtained using a particular battery system, and subsequently by estimating when such a moisture leakage can lead to the end of the battery life. For example, if the battery is stored in a humid environment, then the difference in partial pressures inside and outside the battery will be minimal, which will reduce the rate of moisture loss, so that the battery life can be extended. If the same battery is stored in a particularly dry and hot environment, this can significantly reduce the expected service life due to accelerated moisture loss.

Metal / metal, metal / glass, metal / ceramics, glass / glass, semiconductor / semiconductor and metal / semiconductor sealing layers

Numerous means can be used to form a sealed or well-sealed joint between solid materials that can act as a sealer for the chemical component of a battery. Typical methods for forming a proper hermetic mechanical connection between solid materials include low-temperature soldering, high-temperature soldering, and welding. In most cases, these methods can be regarded as similar, since they all include heat treatment of both base materials (materials to be bound, which can be either homogeneous or heterogeneous materials), and filler material, which binds together two base materials. . The main differences between these methods are the specific temperature values used to heat the materials according to each method, and how these temperatures affect the properties of each material when used for a long period of time. In particular, both during high-temperature brazing and low-temperature brazing, a temperature can be used which is higher than the liquidus temperature of the filler material, but lower than the solidus temperature of both base materials. The main difference between high-temperature soldering and low-temperature soldering is the specific temperature used. For example, if the applied temperature is below 450 ° C, the method can be called low-temperature brazing, and it can be referred to as high-temperature brazing, if the applied temperature is above 450 ° C. However, when welding, a temperature that is higher than the liquidus of the filler material and base materials can be used.

Each of the above methods can be applied to different combinations of materials, and specific combinations of materials can be linked to each other using more than one of these methods. The optimal choice among these methods of combining two materials can be determined by any number of characteristics, including, among others, specific material properties and liquidus temperature an acceptable level of mechanical or surface damage to bonded materials using each method. In some examples according to the present invention, the materials used to join the two materials may include pure metals, such as gold, silver, indium and platinum. They can also include alloys such as silver-copper, silver-zinc, copper-zinc, copper-zinc-silver, copper-phosphorus, silver-copper-phosphorus, gold-silver, gold-nickel, gold-copper, alloys of indium and aluminum-silicon. They may also include active alloys for high-temperature soldering, for example, titanium active alloys for high-temperature soldering, which may include gold, copper, nickel, silver, vanadium or aluminum. Other materials for high-temperature soldering may be used that can meet the sealing requirements mentioned in this description.

Different combinations of materials for each of these binding methods may include metal / metal, metal / glass, metal / ceramic, glass / glass, semiconductor / semiconductor, and metal / semiconductor.

In the example of the first type, a metal-to-metal sealing layer may be formed. Low-temperature brazing, high-temperature brazing and welding are methods that are very often used to make a metal / metal connection. Since the properties of different metals can differ quite strongly from each other, the temperature of the transition of the metal to the liquid state can usually be considered a decisive indicator when choosing the method of binding to the desired metal, for example, the base metal can have such a low transition temperature to the liquid state. that it will melt quickly at soldering temperatures, or the base metal may have such a high transition temperature to a liquid state that it will not chemically react to temperatures have a soldering to form an appropriate bond.

In another example, a metal-glass sealing layer may be formed. Due to the heterogeneity of metal and glass as materials, typical methods of combining metal with metal may not provide for the binding of metals with glass. For example, typical filler materials used in metal / metal low-temperature soldering may bind well with metal, but may not react with glass to create a bond with its surface during heat treatment. One of the ways to overcome this problem may be the use of other materials, such as epoxies, which bind to both materials. Typical epoxy resins have side hydroxyl groups in their structure, which can provide strong bonding with inorganic materials. Epoxy can be an easy and inexpensive means of binding materials, due to the possibility of universal bonding with many types of surfaces. Epoxy resins can be easily cured with equal success both before and after application using many methods, such as mixing chemicals that are then quickly applied, heat, light or other types of radiation that transfer energy to the epoxy resin, causing a binding / curing reaction. or using other methods. Many different types of epoxy resins may have different acceptability for different applications depending on many different properties, including, among others, adhesion strength, ease of use, curing method, cure time, adhesives, and many others. To achieve a fully hermetic seal with epoxy, it is necessary to take into account the rate of leakage of certain fluids through the epoxy. However, an airtight seal using epoxy resin provides the flexibility to use copper alloys for wires or contacts while maintaining the sealing layer's tightness, unlike less electrically conductive materials that are necessary for other types of binding or creating a hermetic seal. However, epoxy sealing layers, as a rule, are stable in much more limited ranges of operating temperatures than when other binding methods are used, and may also have a significantly lower bond strength.

In another example, a cermet sealing layer can be formed. Brazing can be considered as a standard method of obtaining a metal-ceramic bond, and there are many recognized and approved methods for obtaining a sealed sealing layer between materials. They may include a molybdenum-manganese / nickel plating method in which molybdenum and manganese particles are mixed with glass additives and volatile carriers to form a coating that is applied to the ceramic surface in relation to which high-temperature brazing will be performed. This coating is treated and then coated with nickel and additional processing is carried out to enable easy high-temperature soldering with the use of standard methods and filler materials.

Another common method of soldering is the application of a thin film. In this method, a combination of materials can be applied to a non-metallic surface using a physical vapor deposition (PVD) method. The choice of applied materials may depend on the desired material properties or layer thickness, and sometimes put many layers. This method has many advantages, including a large variety of possible metals for use, as well as speed and reliable continuous success when used with standard materials. However, there are disadvantages, including the need to use specialized PVD-equipment for coating, the need to use complex masking techniques if masking is required, and geometric constraints with ceramics that can impede the achievement of uniform coating thickness. The PVD layer may include components such as titanium, zirconium and hafnium, and in some examples may have a thickness of from 100 to 250 nanometers. In some examples, an inert overlayer may be applied that contains, as examples without limiting, components such as gold, palladium, platinum, or silver.

Binding of Nanofoil® Material

Commercially available Nanofoil® is a nanotechnological material produced by Indium Corporation, which can be an important example of when sealing metal, ceramic and / or semiconductor battery sheaths may be required. In some examples, it may be desirable that any thermal effects during the formation of the sealing layer are as localized as possible in the sealing layer itself. Composite materials, such as Nanofoil®, can provide significant thermal localization with the simultaneous formation of hermetically bonded sealing layers. Nanofoil® type composite films can be made from hundreds or thousands of levels of nanoscale films. In one example, a reactive multilayer foil is made by vapor deposition of thousands of alternating layers of aluminum (Al) and nickel (Ni). These layers can be several nanometers thick. When activated by a small pulse of local energy from electrical, optical or thermal sources, the foil reacts exothermically. The resulting exothermic reaction transmits a measurable amount of energy in thousandths of seconds with heating on surfaces to very high local temperatures, but can be designed not to deliver the entire amount of energy that would increase the temperature in metal, ceramic or semiconductor elements.

Sealing S-Bond®

Another example, analogous to the binding of Nanofoil®, may be the binding of S-Bond®. The S-Bond material may contain a conventional solder alloy base with the addition of titanium or other rare earth elements to the material, and it is manufactured by S-Bond Technologies. Active materials, such as titanium, react with oxides or other inert materials at the interface and are either chemically bonded to them or transported to the solder melt. When heated, S-bond® materials can melt, but at the same time contain a thin surface layer of oxide. When this surface oxide layer is destroyed, active material reactions occur on the surface bonding / sealing layer sites. The oxide can be destroyed by scraping, but it can also be destroyed by ultrasound. Therefore, a surface reaction can be initiated at a relatively low temperature, and a bond can be formed with materials with which it can be difficult to create a bond in another way. In some examples, the S-Bond® material may be combined with Nanofoil® material to form a structure that can be locally connected without significant heat load to the rest of the battery system.

Silicon bonding

In some examples, the binding of silicon can be performed using the material S-Bond®. A composition containing S-Bond® 220M can be applied in some examples to form an interface that can be soldered. S-Bond® 220M can be applied to the silicon surface for binding / sealing at temperatures in the range of 115-400 ^o C. Thus, the cans of a portion of silicon can be heavily doped at the closed end or by using doped films such as POCl, by implantation, or using other methods of doping. Other means may include oxidation of the semiconductor body, and then chemical etching of the oxide in areas where doping is required. The doped regions can then be exposed to titanium and heated to form a silicide. Areas of silicon cans that are used to form the sealing layers may contain S-Bond 220M material that has been applied to them and is heated to the appearance of moisture on the silicon surface or the surface of the silicide. In some examples, a film of Nanofoil® may be applied in the sealing area for subsequent activation. The chemical component of the battery, electrolyte and other structures can form half a can, and then the two halves can be combined. With simultaneous activation by ultrasound and the activation of Nanofoil® material, a low-temperature hermetic seal can be quickly formed.

Battery module thickness

When designing battery components for biomedical applications, you can adjust various parameters by finding a trade-off between technical and functional requirements as well as safety requirements. The thickness of a battery component can be an important and limiting parameter. For example, in the field of application of an optical lens, the ability of a device to be comfortable when worn by a user may depend to a large extent on the thickness of a biomedical device. Therefore, there are important aspects when designing batteries to make them thinner. In some examples, the thickness of the battery can be determined by the combined thickness of the upper and lower sheets, the release sheets and the adhesive layer. Practical aspects of fabrication may require compliance of certain film thickness parameters with standard values for available sheet material. In addition, films can have minimum thickness values that can be set based on technical considerations regarding chemical compatibility, liquid / gas permeability, surface treatment, and compatibility with coatings that can be deposited on top of film layers.

In some examples, the desired or target thickness of the finished battery component may be a component thickness less than 220 microns. In these examples, this required thickness may be due to the three-dimensional geometry of the illustrative ophthalmic lens device, and it may be necessary to fit the battery component inside the existing volume formed by the hydrogel lens shape, taking into account a certain level of end-user comfort, biocompatibility and acceptance criteria. This lens volume and its effect on the thickness requirements of a battery component may depend on the overall technical requirements for the thickness of the device, as well as the technical requirements for the width, angle of cone and internal diameter of the device. Another important aspect of the configuration of the final battery component may relate to the volume available for active chemicals and battery materials, taking into account the specific configuration of the battery component in relation to the chemical energy produced, which may result from this configuration. This resulting chemical energy can subsequently be balanced to meet the power requirements of a functional biomedical device for the targeted conditions of its service life and operation.

Battery module width

There are many applications in which biocompatible power supply elements or batteries of the present invention can be used. In general, the requirement for the width of the battery is mainly due to the scope of its application. In the illustrative case, a contact lens battery system may have limitations in the specifications for the width of a component of a modular battery. In some examples of an ophthalmic device, where the device has a function with variable optical properties, powered by a battery component, a portion of the device with variable optical properties may occupy a central spherical region of about 7.0 mm in diameter. The elements of the battery in these examples can be considered as a three-dimensional object, which is placed as a conical ring skirt around the central optical section and forms a truncated conical ring. If the required maximum diameter of a rigid insert is 8.50 mm, and the angle tangent to a sphere of a certain diameter can be specified (for example, a diameter of approximately 8.40 mm), then the geometry can determine the permissible width of the battery. There are geometric models that can be used to calculate the desired technical parameters of the resulting geometric shape, which in some examples may be a truncated cone, deployed in the form of a sector of an annular zone.

The width of the unfolded battery can be due to two components of the cell: the active components of the battery and the width of the sealing layer. In some examples relating to ophthalmic devices, the target thickness may be from 0.100 mm to 0.500 mm per side, and the width of the active components of the battery can be set to approximately 0.800 mm Other biomedical devices may have other configuration limitations, but the principles for flexible flat battery cells can be applied in the same way.

Battery module flexibility

Another criterion for matching the battery configuration and the configuration of the corresponding devices that use battery-based energy sources is the flexibility of the battery component. There are many advantages offered by flexible battery forms. For example, a flexible battery module may facilitate the aforementioned ability to manufacture a two-dimensional (2D) flat-shaped battery. Subsequently, form flexibility may allow the conversion of a two-dimensional battery to an appropriate three-dimensional (3D) form, for fit into a biomedical device, such as a contact lens.

In another example of the advantages that may be provided by the flexibility of the battery module, it is shown that if the battery and the subsequent device are flexible, then advantages may arise regarding the use of the device. In one example, the shape of a contact lens of a biomedical device may have the advantages of inserting / removing a contact lens based on a substrate liner, which may more closely resemble the insertion / removal of a standard, unfilled hydrogel contact lens.

The number of bends may be important for battery design. For example, a battery that allows only one bend when moving from a flat shape to a shape acceptable for a contact lens may differ significantly in configuration from the battery, made with the possibility of multiple bends. Bending of the battery can also exceed its resistance to mechanical bending. For example, the electrode may be physically configured to flex without breaking, but the mechanical and electrochemical properties of the electrode may change due to the bending. Changes resulting from bending can manifest immediately, for example, in the form of changes in impedance, or bending can cause changes that become noticeable only during tests conducted after long-term storage.

Battery Shape Aspects

Requirements for the shape of the battery may be due, at least in part, to the application of the battery. Traditional battery shapes can be cylindrical shapes or rectangular prisms made of metal, and they can be used for products that require large amounts of energy for a long time. Such applications are large enough to contain batteries with a large size. In another example, flat solid-state batteries are thin rectangular prisms, usually formed on hard silicon or glass. In some examples, these flat solid-state batteries can be manufactured using silicon wafer processing techniques. Other battery sizes, low-power but flexible batteries, can be made in the form of packages using thin foil or plastic, which contain the chemical elements of the battery. These batteries can be flattened (2D) and designed to function with moderate extra-planar curvature (3D).

In some application examples of a battery in accordance with the present invention, in which batteries can be used in lenses with variable optical properties, the size may require creating a three-dimensional curvature of the battery component, where the radius of this curvature may be about 8.4 mm The nature of such a curvature can be considered relatively sharp and, as a comparison, can approach the type of curvature of a person’s fingertip. The nature of the relatively sharp curvature creates difficulties in production. In some examples of the present invention, a component of a modular battery may be designed in such a way that it can be made flat, two-dimensional, and subsequently formed into a three-dimensional shape with relatively large curvature.

Battery Separators

Batteries of the type described in the present description may use a separator material that physically and electrically separates parts of the anode and anode current collector from parts of the cathode and cathode current collector. The separator may be a membrane permeable to water and dissolved electrolyte components; however, as a rule, it may be non-conductive. Although a large number of commercially available separator materials may be known to those skilled in the art, the new form of the present description may present unique limitations in the task of selecting, processing, and using the separator.

Since the configurations of the present description may have ultrathin profiles, the choice may be limited to the thinnest of the available separator materials. For example, separators with a thickness of about 25 microns may be desirable. Some examples, which may be advantageous, may be about 12 microns thick. There are many acceptable commercial separators, including single-layer microfiber, microporous polyethylene and / or three-layer polypropylene-polyethylene-polypropylene (PP / PE / PP) separation membranes, such as those manufactured by Celgard (Charlotte, North Carolina , USA). A desirable example of a spacer material may be a Celgard M824 PP / PE / PP three-layer membrane having a thickness of 12 microns. Alternative examples of separator materials suitable for the examples of the present invention may include separating membranes containing regenerated cellulose (eg, cellophane).

Although PP / PE / PP trilayer separation membranes may have advantages due to their thickness and mechanical properties due to their polyolefin nature, they may also have a number of disadvantages that must be overcome to make them suitable for the examples of the present invention. Rolled or sheet trilayer PP / PE / PP separator materials may have numerous folds or other shape irregularities that may be undesirable for micron level tolerances applicable to the batteries described in this document. In addition, high-precision cutting of polyolefin separators may be required for inclusion in these configurations, which may involve laser cutting as one example of how to form individual current collectors of desired shapes with tight tolerances. Due to the polyolefin nature of these separators, some laser cutters suitable for micromanufacturing that can use laser wavelengths, for example, 355 nm, will not be able to cut polyolefins. Polyolefins do not absorb laser energy in perceptible amounts and, thus, are indestructible. Finally, polyolefin separators, by their nature, cannot be wetted with aqueous electrolytes, which are used in the batteries described in these documents.

However, there are ways to overcome these inherent limitations of polyolefin-type membranes. In order to subject a microporous separating membrane to a high-precision laser cutter for cutting parts into arcuate segments or other preferential separator configurations, the membrane may be required to be flat and wrinkle-free. If these two conditions are not fulfilled, the separation membrane cannot be completely cut, since the cutting beam can be weakened as a result of a loss of focus or other dissipation of the incident laser energy. In addition, if the separation membrane is not flat and wrinkle-free, the accuracy of the shape and the geometric tolerances of the separation membrane cannot be achieved sufficiently. The tolerances for the separators in the current examples may, for example, be +0 microns and -20 microns with respect to characteristic lengths and / or radii. There may be advantages for tighter tolerances of +0 microns and -10 microns and additionally for tolerances of +0 microns and -5 microns. The separator raw material can be made flat and wrinkle-free by temporarily laminating the material on a float glass substrate with an appropriate low-volatile liquid. Low-volatile fluids may be preferable to temporary adhesives due to the fragility of the separation membrane and the amount of processing time that may be required to release the separation membrane from the adhesive layer. In addition, in some examples, the preparation of a flat and wrinkle-free separation membrane on float glass with the use of a liquid turned out to be much easier than with the use of an adhesive. Before laminating, the separation membrane can be cleaned of solid particles. This can be done by ultrasonic cleaning of the separation membrane to remove any solid particles adhering to the surface. In some examples, separation membrane treatment can be performed in a suitable low particle content medium, such as a laminar box or a clean room of at least 10,000 class. In addition, float glass substrate can be cleaned of particles by washing with an appropriate solvent, ultrasonic cleaning and / or wiping wipes for clean rooms.

Although a variety of low volatile fluids can be used for the mechanical purpose of laminating microporous polyolefin separating membranes on a float glass substrate, specific requirements can be applied to liquids to facilitate subsequent laser cutting of individual separator shapes. One requirement may be that the fluid has sufficiently low surface tension to penetrate the pores of the separator material, as can be easily ascertained by visual inspection. In some examples, the separator material turns white to transparent when the liquid fills the micropores of the material. It may be desirable to choose a fluid that may be favorable and “safe” for workers who will perform the preparation and cutting operations of the separator. It may be desirable to choose a liquid whose vapor pressure will be low enough so that there is no noticeable evaporation during the treatment period (about 1 day). Finally, in some examples, the liquid may have sufficient solvating ability to dissolve the predominant UV absorbers, which may facilitate laser cutting. In one example, it turned out that a 12% (by weight) solution of avobenzone (UV absorber) in benzyl benzoate (solvent) can meet the above requirements and may be suitable for facilitating laser cutting of polyolefin separators with high accuracy and within tolerances at small intervals time and without an excessive number of passes of the laser cutter beam. In some examples, separators can be cut using an 8 V 355 nm solid state laser with diode pumping and nanosecond pulses using this approach, and the laser can be tuned to a low attenuation power (for example, 3% power), an average speed from 1 to 10 mm / with and only 1 to 3 passes of the laser beam. Despite the fact that this UV-absorbent oily composition has proven to be an effective aid to lamination and cutting, specialists in this field can use other oily compositions without any restrictions.

In some examples, the separator can be cut secured to float glass. One of the advantages of separators fixed on a carrier of polished sheet glass and cut by a laser can be a very high density of separators that can be cut from a single sheet of separator material, which makes them look like semiconductor crystals that can be tightly placed on a silicon substrate. Such an approach can provide the advantages of economies of scale and parallel processing characteristic of semiconductor technologies. In addition, the formation of substandard separation membranes can be minimized. After the separators are cut, the oily aid fluid can be removed by multi-stage extraction with miscible solvents, the latter extraction can be performed with a highly volatile solvent such as isopropyl alcohol in some examples. Separate separators after extraction can be stored indefinitely in any suitable low particle size medium.

As stated above, polyolefin separating membranes may be hydrophobic in nature and may require wetting with aqueous surfactants used in the batteries of the present invention. One approach to ensuring the wettability of separation membranes can be treatment with oxygen plasma. For example, dividers can be processed from 1 to 5 minutes with 100% oxygen plasma in a wide range of power settings and oxygen consumption. Despite the fact that such an approach can improve wettability for some time, it is known that modifying surfaces with plasma provides only a temporary effect that cannot last long enough for reliable wetting of electrolyte solutions. Another approach to improving the wettability of separation membranes may be to treat the surface by inserting suitable surfactants into the membrane. In some cases, the surfactant can be used in combination with a hydrophilic polymer coating that remains inside the pores of the separation membrane.

Another approach to ensuring the persistence of hydrophilicity, provided by oxygen plasma treatment, may consist in the subsequent treatment with a suitable hydrophilic organosilane. Thus, oxygen plasma can be used to activate and provide functional groups over the entire surface area of the microporous separator. Then organosilane can covalently bind and / or non-covalently stick to the surface treated with plasma. In examples where organosilane is used, the characteristic porosity of the microporous separator may not undergo noticeable changes; single layer surface coating may also be possible and desirable. Known in the field of methods of embedding surfactants in combination with polymer coatings may require strict control over the actual amount of coating deposited on the membrane, and therefore may exhibit technological instability. In extreme cases, the pores of the separator can become blocked, thus adversely affecting the functionality of the separator during operation of the electrochemical cell. An example of an organosilane suitable for the present description may be 3-aminopropyltriethoxysilane. Other hydrophilic organosilanes may be known to those skilled in the art, which can be used without restriction.

Another way to ensure the wettability of separation membranes with aqueous electrolytes may be to embed a suitable surfactant in the electrolyte composition. One consideration when choosing a surfactant to ensure the wettability of the separation membranes can be the effect that the surfactant can have on the activity of one or more electrodes inside the electrochemical cell, for example, by increasing the total electrical resistance of the cell. In some cases, surfactants may have superior anti-corrosion properties, in particular in the presence of zinc anodes in aqueous electrolytes. It is known that zinc can be an example of a material that slowly interacts with water to release gaseous hydrogen, which may be undesirable. A number of surfactants may be known to those skilled in the art, limiting the rate of said interaction to advantageous levels. In other cases, the surfactant may interact so strongly with the surface of the zinc electrodes that the functioning of the battery may be difficult. Consequently, the choice of appropriate types of surfactants and their loading levels should be given special attention to ensure the wettability of the separator without adversely affecting the electrochemical performance of the element. In some cases, many surfactants can be used, with some giving a wettability to the separation membrane, and others enhancing the anti-corrosion properties of the zinc anode. In one example, the hydrophilic treatment of the separation membrane is not carried out, but one or many surfactants are added to the electrolyte in an amount sufficient to ensure the wettability of the separation membrane.

Separate separators can be embedded in a bicuspid microbattery by directly placing them in part of one bicuspid configuration or on either side of it.

Polymerized Battery Cell Separators

In some battery configurations, the use of a separate separator (as described in the previous section) can be excluded due to various reasons, such as cost, availability of materials, quality of materials or processing complexity of some material options, as examples that are not restrictive.

The method of obtaining a homogeneous, mechanically reliable, formed in place of the separator may be the use of UV-curable hydrogel formulations. In various industries, for example, in the industry of production of contact lenses, many permeable hydrogel compositions are known. An example of a hydrogel widely used in the contact lens industry is a poly (hydroxyethyl methacrylate) cross-linked gel, or simply pHEMA. For a variety of applications of the present invention, pHEMA has many attractive properties for use in Leclanche or zinc carbon batteries. Typically, the moisture content of the pHEMA gel in the hydrated state is approximately 30-40 percent, and the modulus of elasticity is approximately 0.7 MPa (about 100 psi) or more. In addition, those skilled in the art can adjust the moisture content and modulus of elasticity of cross-linked hydrogels by embedding additional hydrophilic monomeric (eg, methacrylic acid) or polymeric (eg, polyvinylpyrrolidone) components. Thus, the moisture content and, more specifically, the ion permeability of the hydrogel can be adjusted by changing the composition.

In some examples, a particular advantage is that the hydrogel composition suitable for casting and polymerization may contain one or more diluents to speed up the processing. The volatility of the diluent is chosen so that the mixture suitable for casting can be pushed into the cavity, and then allow enough time for drying to remove the component of the volatile solvent. After drying, bulk photopolymerization can be initiated by exposure to actinic radiation with a corresponding wavelength, such as blue UV radiation with a wavelength of 420 nm, for a selected photoinitiator, for example CGI 819. Using a volatile diluent, you can provide the desired working viscosity to facilitate the formation of a uniform layer of polymerized material. A volatile diluent can also provide an effective reduction of surface tension, especially in the case when highly polar monomers are incorporated. Another aspect that may be important to obtain a uniform layer of polymerized material in the cavity may be a working viscosity. Conventional low molar mass reactive monomers have, as a rule, a low viscosity, which can usually be only a few centipoise. To ensure effective control of the viscosity of the separator material suitable for casting and polymerization, you can choose to incorporate into its composition a polymer component with a high molar mass and with a known degree of compatibility with the polymerized material. Examples of high molar mass polymers that may be suitable for incorporation into examples of formulations may include polyvinylpyrrolidone and polyethylene oxide.

In some examples, a separator suitable for casting and polymerization can advantageously be placed in the formed cavity, as described above. In alternative examples, the cavity may be missing during the polymerization. Instead, the composition suitable for casting and polymerization of the separator can be applied to a substrate containing an electrode, for example, made of galvanized brass, and then subjected to actinic radiation using a photomask to selectively polymerize the separator material in specified zones. The unreacted material of the separator can then be removed by exposure to the appropriate washing solvents. In these examples, the material of the separator can be designated as a photo-structured separator.

Multicomponent splitter compositions

A suitable separator in accordance with examples of the present invention may have a number of properties important for its operation. In some examples, the separator may preferably be formed so as to create a physical barrier so that the layers on each side of the separator do not have physical contact with each other. Therefore, a layer may have an important characteristic of uniform thickness, since, although a thin layer may be desirable for many reasons, the presence of a layer without voids and gaps may be significant. In addition, it may be desirable that the thin layer has a high permeability, providing a free flow of ions. The separator also requires optimal moisture absorption to optimize the mechanical properties of the separator. Thus, the composition may contain a crosslinking component, a hydrophilic polymer component, and a solvent component.

The crosslinking agent may be a monomer with two or more polymerizable double bonds. Suitable crosslinking agents can be compounds with one or more polymerizable functional groups. Examples of suitable hydrophilic crosslinkers can also include compounds with one or more polymerized functional groups, as well as hydrophilic functional groups, such as polyester, amide, or hydroxyl groups. Specific examples may include TEGDMA (tetraethylene glycol dimethacrylate), TrEGDMA (triethylene glycol dimethacrylate), ethylene glycol dimethacrylate (EHDMA), ethylenediamine, dimethylacrylamide, glycerol dimethacrylate, and combinations thereof.

The amount of crosslinking agent that can be used in some examples may range from, for example, from about 0.000415 to about 0.0156 mol per 100 grams of reaction components in the reaction mixture. The amount of hydrophilic crosslinking agent used can generally be from about 0 to about 2% by weight. and, for example, from about 0.5 to about 2% by weight. It may be desirable to select hydrophilic polymer components capable of increasing the viscosity of the reaction mixture and / or increasing the degree of hydrogen bonds with a slowly reacting hydrophilic monomer, such as high molecular weight hydrophilic polymers.

High molecular weight hydrophilic polymers provide improved wettability and in some examples can improve the wettability of the separator of the present invention. In some non-limiting examples, it can be assumed that high molecular weight hydrophilic polymers are hydrogen bond receptors, which in fact become more hydrophilic in aqueous media with hydrogen bonds. Lack of water may contribute to the incorporation of a hydrophilic polymer into the reaction mixture. In addition to the specially named high molecular weight hydrophilic polymers, it can be expected that any high molecular weight polymer will be suitable for the present invention, provided that, when the polymer is added to the silicone hydrogel composition example, the hydrophilic polymer (a) does not stand out significantly in a separate phase the reaction mixture and (b) increases the wettability of the obtained cured polymer.

In some examples, it is preferred that the high molecular weight hydrophilic polymer is soluble in the diluent at operating temperatures. Production processes that use water or water-soluble diluents, such as isopropyl alcohol (IPA), may be preferred examples because of their simplicity and low cost. In these examples, high molecular weight hydrophilic polymers that dissolve in water at operating temperatures may also be preferred.

Examples of high molecular weight hydrophilic polymers include, without limitation, polyamides, polylactones, polyimides, polylactams, and functionalized polyamides, polylactones, polyimides, polylactams, such as PVP or its copolymers, or alternatively DMA, functionalized by DMA copolymerization with a lower molar hydroxyl-functionalized monomer, such as hydroxyethyl methacrylate (HEMA), followed by reaction of the hydroxyl groups of the obtained copolymer with materials containing radical polymer studied groups. Examples of high molecular weight hydrophilic polymers include, without limitation, poly-N-vinyl pyrrolidone, poly-N-vinyl-2-piperidone, poly-N-vinyl-2-caprolactam, poly-N-vinyl-3-methyl-2- caprolactam, poly-N-vinyl-3-methyl-2-piperidone, poly-N-vinyl-4-methyl-2-piperidone, poly-N-vinyl-4-methyl-2-caprolactam, poly-N-vinyl 3-ethyl-2-pyrrolidone and poly-N-vinyl-4,5-dimethyl-2-pyrrolidone, polyvinyl imidazole, poly-N-N-dimethyl acrylamide, polyvinyl alcohol, polyacrylic acid, polyethylene oxide, poly-2-ethyloxazoline, polysaccharides heparin, polysaccharides, their mixtures and copolyme (including block copolymers or random, branched-chain, multi-chain, comb-like or star-shaped), where poly-N-vinylpyrrolidone (PVP) can be a desirable example where PVP is added to a hydrogel composition with a low-level inter-penetrating polymer network friction and low dehydration.

Additional components or additives known to those skilled in the art may also be included. Additives may include, in particular, compositions with ultraviolet absorption, photoinitiators, such as CGI 819, reactive dyes, bactericidal compositions, pigments, photochromic compositions, release agents, combinations thereof, etc.

The method associated with separators of these types may also include the preparation of a CGI 819; and then mixing with polyvinylpyrrolidone (PVP), hydroxyethyl methacrylate (HEMA), ethylene glycol dimethacrylate (EGDMA) and isopropyl alcohol (IPA); and then curing the resulting mixture with a heat source or photon exposure. In some examples, the effect of photons can be carried out in conditions where the photon energy corresponds to the wavelength in the ultraviolet part of the electromagnetic spectrum. The present invention includes other methods of initiating polymerization, which is essentially performed in polymerization reactions.

Connections

Connections may allow current to flow to and from the battery in conjunction with an external circuit. Such connections may interact with the environment inside and outside the battery and may cross the boundary or sealing layer between these environments. These connections can be thought of as tracks connecting the external circuit, passing through the sealing layer of the battery and subsequently connecting to current leads inside the battery. As such, these compounds may have several requirements. Connections outside the battery may look like typical PCB tracks. They can be soldered or otherwise connected to other tracks. In the example where the battery is a physical element separate from the printed circuit board containing the integrated circuit, the battery connections can provide communication with the external circuit. This bond can be formed using solder, an electrically conductive tape, electrically conductive ink, or an epoxy compound, or other means. For connecting lanes, it may be necessary to remain intact in an environment outside the battery, such as not rusting in the presence of oxygen.

Since the joint passes through the sealing layer of the battery, it may be extremely important that the joint be compatible with the material of the sealing layer and ensure tightness. Adhesion may be required between the sealing layer and the joint in addition to the adhesion that may be required between the sealing layer and the insulating shell of the battery. If electrolyte and other materials are present inside the battery, it may be necessary to maintain the integrity of the sealing layer. Connections, which, as a rule, can be metallic, can be known as points of destruction in the insulating shell of a battery. Electrical potential and / or current flow may increase the tendency for the electrolyte to leak along the junction. Accordingly, a joint may be required to design, maintaining the integrity of the sealing layer.

Inside the battery, the connections can interact with the down-conductors or can form the down-conductors themselves. Therefore, connections may need to meet the requirements for current leads described in this document, or it may be required to form an electrical connection to such current leads.

One class of potential compounds and current leads is a metal foil. Such a foil is available, having a thickness of 25 μm or less, which makes it acceptable for very thin batteries. This foil can also be found with low levels of roughness and surface contamination (two factors that may be critical for battery performance). Foil may include zinc, nickel, brass, copper, titanium, other metals and various alloys.

Current leads and electrodes

It is assumed that many of the configurations of the collector and electrode are formed by applying metal films to the side wall or by using metal wire as substrates to form a collector and electrodes. Their examples have been illustrated. However, there are some configurations that use other current leads or electrode designs for double-leaf batteries.

In some examples of carbon-zinc galvanic cells and Leclanche cells, the cathode current collector may be a sintered carbon rod. A material of this type may present a technical difficulty for the thin electrochemical cells of the present invention. In some examples, printed carbon ink can be used instead of a sintered carbon rod in thin electrochemical cells for a cathode current collector, and in these examples the resulting device can be formed without substantially degrading the resulting electrochemical cell. Typically, these carbon inks can be applied directly to insulating materials, which may contain polymer films or, in some cases, metal foil. In examples in which the insulating film may be a metal foil, carbon ink may be required to protect the underlying metal foil from chemical damage and / or corrosion by the action of an electrolyte. In addition, in these examples, the conductor containing carbon ink may be required to provide electrical conductivity from within the electrochemical cell beyond the electrochemical cell, ensuring tightness around or through the carbon ink.

Carbon ink can also be applied in layers that have a marginal and relatively small thickness, for example from 10 to 20 microns. In the configuration of a thin electrochemical cell, in which the total internal thickness of the insulating sheath can be only from about 100 to 150 microns, the thickness of the carbon ink layer can be a significant proportion of the total internal volume of the electrochemical cell, thus adversely affecting the electrical characteristics of the cell. Additionally, the small thickness of the battery as a whole and the collector in particular may imply a small cross-sectional area of the collector. Since the resistance of the track increases with the length of the track and decreases with increasing cross-sectional area, the resistance of the collector can directly depend on its thickness. The volume resistivity of carbon ink may not be sufficient to meet the impedance requirements of thin batteries. It is also believed that adding silver or other conductive metals to inks can lower the resistance and / or layer thickness, but these metals can introduce new problems, such as incompatibility with new electrolytes. Considering these factors, in some examples, it may be desirable to create highly efficient thin electrochemical cells of the present invention by using thin metal foil as a current collector or by applying a thin metal film on the underlying insulating layer of the polymer to function as a current collector. Such a metal foil can have a significantly lower resistance, thus allowing it to meet the requirements for electrical resistance with a much smaller thickness than printed carbon ink.

In some examples, one or more double-leaf configurations may be used as a substrate for electrodes and current leads, or as a current lead as such. In some examples, depositions may be performed on the surface of the metals of the bicuspid configuration. For example, the metal flaps of a bicuspid configuration can serve as a substrate for a sprayed metal or a metal overlay of a current lead. Examples of metal overlays used as cathode current leads can be titanium-tungsten adhesive layers (Ti-W) and conducting titanium layers (Ti). Examples of metal overlays used as anode current leads are Ti-W adhesive layers, conductive gold layers (Au) and indium deposition layers (In). In other examples, the anode and cathode current leads may contain nickel, brass, aluminum, and copper. Unusual materials may include graphene and carbon nanotubes.

The total thickness of the PVD layers may be less than 500 nm. If multiple layers of metals are used, compatibility of the electrochemical and protective properties with the battery may be necessary. For example, copper can be applied to the germinal layer by electrolytic deposition to create a thick conductive layer. Additional layers can be applied to copper. However, copper may be electrochemically incompatible with some electrolytes, especially in the presence of zinc. Accordingly, when copper is used as a layer in a battery, it may be necessary to sufficiently isolate it from the battery electrolyte. In an alternative embodiment, the copper can be eliminated or replaced with another metal.

In addition, for the formation of current leads and / or substrates for electrodes, wires made from a variety of materials can be used. In some examples, the metallic conductor may extend into an insulating material, such as glass or ceramics, to provide an insulated electrical contact of the current lead. In some examples, the wire may be made of titanium. In other examples, other base metals may be used, including aluminum, tungsten, copper, gold, silver, platinum, among others, and they may have surface films applied.

Cathodic mixtures and applied coatings

There may be many different variants of the chemical composition of the cathode mixtures, which may correspond to the concepts of the present invention. In some examples, the cathode mixture (the term “cathode mixture” can mean the chemical composition used to form the cathode of a battery) can be used in the form of a paste, gel, suspension or suspension, and may contain a transition metal oxide, such as manganese dioxide, a certain form of electrically conductive additive, for example a certain form of electrically conductive powder, such as carbon black or graphite, as well as a water-soluble polymer, such as polyvinylpyrrolidone (PVP), or some other binding additives. In some examples, other components may be included, such as one or more binders, electrolytic salts, corrosion inhibitors, water or other solvents, surfactants, rheological modifiers and other electrically conductive additives, such as electrically conductive polymers. A properly designed and mixed cathode mixture can have desirable rheological properties that allow you to either dose it to certain areas of the separator and / or cathode current collector, or push it through a grid or stencil in the same way. In some examples, the cathode mixture can be dried before use in the later stages of assembly of a galvanic cell, while in other examples the cathode may contain some or all of the components of the electrolyte and can only partially be dried to a selected moisture content.

The transition metal oxide may, for example, be manganese dioxide. Manganese dioxide, which can be used in a cathode mixture, for example, can be electrolytic manganese dioxide (EMD) due to the favorable additional energy supply that this type of manganese dioxide provides compared to other forms, such as natural manganese dioxide (NMD) or chemical manganese dioxide (CMD). In addition, the EMD used for batteries of the present invention may require a particle size and particle size distribution, which may be beneficial for making cathode mixture pastes / suspensions suitable for application or imprinting. In particular, EMD can be processed to remove significant large particle components that can be considered large compared to other elements, such as the internal dimensions of the battery, the thickness of the separator, the diameters of the dispenser tips, the dimensions of the stencil holes or the dimensions of the grid cells. Particle sizes can also be optimized to improve battery performance, such as internal impedance and discharge capacity.

Grinding is the grinding of solid materials to produce smaller particles than the average size of the particles, using crushing, grinding, cutting, vibrations or other methods. Grinding can also be used to release the materials used from the matrix materials in which they can be included, and for the concentration of mineral substances. A mill is a device that breaks solid materials into smaller pieces by pounding, crushing or cutting. There may be several grinding means and many types of materials processed by such means. Such grinding media may include, among other alternative grinding options, a ball mill, a bead mill, a mortar and pestle, a roller press, a jet mill. One example of grinding may be a jet mill grinding. After grinding, the state of the solid changes, such as particle size, particle size and shape of particles. It is possible to use the method of grinding aggregate to remove or separate contaminants or moisture from the aggregate to obtain a “dry fill” before transportation or structural filling. In some equipment, a combination of different ways of sorting a solid material into a mixture of solid particles, the size of which is limited by the minimum and maximum particle size, is possible. Such processing is called "sorting."

Grinding may be one aspect of the production of a cathode mixture for a uniform distribution of particle sizes of the components of the cathode mixture. The uniformity of the particle size in the cathode mixture can contribute to the achievement of the required viscosity, flow properties, electrical conductivity and other properties of the cathode. Grinding can contribute to the achievement of such properties by controlling the agglomeration or the accumulation of the mass of the components of the cathode mixture. Agglomeration, i.e. the grouping of various elements, which in the case of a cathode mixture can be carbon allotropes and transition metal oxides, can adversely affect the filling process, leaving empty spaces in the desired cathode cavity, as shown in FIG. 11A-11J and described in detail below.

Another important step in the removal of agglomerated or undesirable particles is filtration. Undesirable particles may include particles of too large size, dirt, or other particles that are not explicitly included in the manufacturing process. Filtering can be performed using methods such as, for example, filtering with filter paper, vacuum filtration, chromatography, microfiltration, and other filtering methods.

In some examples, an EMD may have an average particle size of 7 μm with a content of large particles that may contain particles up to about 70 μm. In alternative examples, the EMD can be sieved, further crushed or otherwise separated or processed in order to limit the content of large particles to a level below a certain threshold, for example, 25 microns or below.

In addition, the cathode may contain silver oxides, silver chlorides or nickel oxyhydroxide. Such materials can provide increased capacitance and a lower voltage drop with load during discharging compared to manganese dioxide, both of which are desirable properties for a battery. Batteries based on these cathodes may already have application examples in the industry and in the literature. New microbattery using silver dioxide in the cathode may include a biocompatible electrolyte, such as an electrolyte containing zinc chloride and / or ammonium chloride instead of potassium hydroxide.

Some examples of the cathode mixture may include a polymeric binder. The binder can perform a number of functions in the cathode mixture. The main function of the binder can be to create a sufficient electrical network between the EMD particles and the carbon particles. The second function of the binder may be to enhance mechanical adhesion and electrical contact with the cathode current lead. The third function of the binder can be the effect on the rheological properties of the cathode mixture for its preferential dosing and / or application through a stencil / mesh. Finally, the fourth function of the binder may be the acceleration of the absorption and distribution of the electrolyte inside the cathode.

The choice of the binder polymer, as well as its scope of application, can be effective for the functioning of the cathode in the electrochemical cell of the present invention. If the binder polymer has a high solubility in the electrolyte used, this will interfere with the basic function of the binder - ensuring continuous electrical contact - up to a complete loss of operability of the galvanic cell. On the contrary, if the binder polymer is insoluble in the electrolyte used, the EMD portions may be ionically isolated from the electrolyte, which will lead to a deterioration in the performance of the galvanic cell, such as a decrease in capacitance, a decrease in voltage during open circuit and / or an increase in internal resistance.

The binder may be hydrophobic; it can also be hydrophilic. Examples of binding polymers suitable for the present invention include, among others, PVP, polyisobutylene (PIB), rubber-like triblock copolymers containing styrene end blocks, for example, blocks manufactured by Kraton Polymers, styrene-butadiene block copolymer latexes, polyacrylic acid , hydroxyethylcellulose, carboxymethylcellulose, solid fluorocarbon substances, for example, polytetrafluoroethylene, cements, including portland cement.

One of the components of the cathode mixture may be a solvent. The solvent can be used to wet the cathode mixture, which can contribute to the distribution of particles in the mixture. One example of a solvent may be toluene. Also, a surfactant may be used to moisten and, thus, distribute the cathode mixture. One example of surfactant may be a detergent, such as Triton ^™ QS-44, which can be purchased from the Dow Chemical Company. Triton ™ QS-44 can contribute to the separation of aggregated components of the cathode mixture, providing a more uniform distribution of the components of the cathode mixture.

By production of the cathode, electrically conductive carbon can usually be used. Carbon can form a large number of allotropic or various structural modifications. Different allotropic carbon modifications have different physical properties, which leads to variations in electrical conductivity. For example, the "elasticity" of carbon black can contribute to the bonding of the cathode mixture to the current lead. However, in power supplies that require relatively low amounts of energy, such variations in electrical conductivity may be less important than other beneficial properties, such as density, particle size, thermal conductivity, and relative homogeneity, among others. Examples of allotropic carbon modifications include diamond, graphite, graphene, amorphous carbon (which is informally called carbon soot), bacminsterfullerenes, glassy carbon (also called glass carbon), carbon aerogels, and other possible forms of carbon that can conduct electricity. One example of allotropic carbon modification may be graphite.

In some examples, the cathode may be placed on the wall of a bivalve configuration. The walls of the bicuspid configuration can be metallic in some examples and contain cathode chemicals, such as manganese dioxide, electrolytically applied to them. In other examples, electrolytic manganese dioxide coatings may be formed on cathode leads.

Anodes and anodic corrosion inhibitors

The anodes of the double battery of the present invention may, for example, contain zinc. In traditional zinc carbon batteries, the zinc anode can physically take the form of a can in which the contents of the electrochemical cell can be held. For a battery of the present invention, zinc can be an example, but there are other physical forms of zinc that can provide the desired configuration for ultra-small batteries.

You can find examples of the application of zinc deposition by electrolytic deposition in many industries, for example, for protective and decorative coatings of metal parts. In some examples, electrolytic deposition of zinc can be used to form thin anodes of irregular shape used in batteries of the present invention. In addition, in the process of applying a layer of zinc by electrolytic deposition, it can be applied to form a pattern in many different predetermined configurations. A simple method of applying electrolytically deposited zinc to form a pattern can be treatment using a photomask or a physical mask. In the case of a photomask, the photoresist can be applied to an electrically conductive substrate, and zinc can subsequently be applied to the substrate. The desired application pattern can then be transferred to the photoresist by means of a photomask, thus causing the polymerization of selected areas of the photoresist. Unpolymerized photoresist can be subsequently removed by appropriate dissolution and purification techniques. As a result, patterned areas of an electrically conductive material can be obtained that can be treated with zinc by electrolytic deposition. Although this method may provide an advantage for the shape or configuration of the applied zinc, this approach may require the use of existing photo-structured materials, which may have limited properties for the overall design of the insulating sheath of a galvanic cell. Consequently, to implement some of the thin microbaty configurations of the present invention, new methods for forming a zinc pattern may be required.

After placing the zinc mask, one or more metallic materials can be electrolytically deposited. In some examples, zinc can be applied by electrolytic deposition directly onto an electrochemically compatible anode current collector foil, such as brass. In alternative examples, configurations in which the anodic side of the insulating shell contains a polymer film or a multilayer polymer film that has a metal germ layer, zinc, and / or solutions used for zinc deposition may be chemically incompatible with the underlying metal germ layer. Manifestations of insufficient compatibility may include cracking of the film, corrosion and / or increased release of H ₂ when in contact with the electrolyte of a galvanic cell. In this case, additional metals can be applied to the germ metal to ensure overall chemical compatibility in the system. Indium may be one metal that may be suitable for an electrochemical cell structure. Indium can be widely used as a doping agent in zinc for a battery, and its main function is to provide the anti-corrosion properties of zinc in the presence of an electrolyte. In some examples, indium can be successfully deposited on various germinal layers of metals, such as Ti-W or Au. Indium films with a thickness of 1–3 μm that form on these germinal layers of metal can have low stress and good adhesiveness. In this way, compatibility and stability of the insulating film are achieved on the side of the anode and the current collector attached to it, having an indium layer on top. In some examples, zinc can be deposited on an indium treated surface, and the resulting applied layer can be very non-uniform and granular. This effect can occur at low current densities, for example, 20 amperes per square foot (A / sq. M). Under the microscope, it is clear that zinc grains are formed on the underlying flat deposited layer of indium. In some configurations of the electrochemical cell, the vertical gap for the zinc anode layer may be up to about 5-10 μm in thickness, but in some examples lower current densities can be used to deposit zinc, and the resulting grain irregularities may exceed the desired maximum vertical anode height . Zinc grains can be the result of a combination of high indium electrical overvoltage and the presence of indium oxide.

In some examples, relatively large granular patterns of zinc on indium surfaces can be overcome by increasing the direct current density during electrolytic deposition. For example, the current density of 100 A / sq. m under electrodeposition conditions can lead to zinc granularity, but the size of zinc grains can be significantly reduced compared to a current density of 20 A / sq. m in electrodeposition conditions. In addition, the number of grains can significantly increase at a current density of 100 A / sq. m in electrodeposition conditions. The resulting zinc film can eventually stick together in a more or less uniform layer with only some residual grit elements, while respecting the vertical gap of about 5-10 microns.

An additional advantage of indium in an electrochemical cell may be a reduced release of formed H ₂ , which may be a slow process occurring in aqueous electrochemical cells containing zinc. Indium may preferably be deposited on one or more anode current leads, on the anode itself as a co-precipitated alloying component or as a surface coating on electrolytically deposited zinc. In the latter case, indium surface coatings may be desirable to be applied on site using an electrolyte additive such as indium trichloride or indium acetate. With the introduction of such additives in the electrolyte in small concentrations, indium can spontaneously precipitate on open zinc surfaces, as well as on areas of an open anode current collector.

Zinc and similar anodes commonly used in commercially available primary batteries are generally available in the form of sheets, rods and pastes. The anode of a miniature biocompatible battery may have a similar shape, for example, thin foil, or may be deposited as described above. The properties of this anode may differ significantly from the properties of the anodes of existing batteries, for example, due to differences in impurities or surface treatment associated with the processes of mechanical processing and electrolytic deposition. Accordingly, the electrodes and the electrolyte may require special design to meet the requirements for capacity, impedance and shelf life. For example, to optimize the performance of an electrode, special parameters of an electrolytic deposition method, an electrolytic bath composition, a surface treatment and an electrolyte composition may be required.

Battery layout and manufacturing

The layout and technology of the battery can be closely related. As described in the previous sections of the present invention, a battery may have the following elements: a cathode, an anode, a separator, an electrolyte, a cathode current lead, an anode current lead, and a bivalve sealant. In some examples, configurations may have dual-purpose components, such as using a bivalve metal shell as well as a current lead. In terms of relative volume and thickness, almost all of these elements can have the same volume, with the exception of the cathode. In some examples, electrochemical systems may require a cathode volume that is approximately 2-10 (two to ten) times the volume of the anode, due to significant differences in mechanical density, energy density, discharge efficiency, material purity, and the presence of binders, fillers and conductive agents .

Aspects of battery biocompatibility

Batteries according to the present invention may have important safety and biocompatibility aspects. In some examples, batteries for biomedical devices must meet requirements that go beyond typical application scenarios. In some examples, configuration aspects regarding load cases may be taken into account. For example, it may be necessary to consider the safety of the electronic contact lens in cases where the user breaks the lens in the process of inserting or removing it. In another example, aspects of the configuration may take into account the likelihood of a user striking a foreign object in the eye. In additional examples, load conditions that can be considered when developing configuration parameters and constraints may refer to the user's wearing probability in adverse environmental conditions, such as underwater or high-altitude environments, as non-restrictive examples. .

The safety of such a device can be affected by: the materials with which or from which the device is made; the number of materials used in the manufacture of the device; and an insulating shell applied to separate the devices from the environment on the body or inside the body. As an example, pacemakers can be a typical example of a biomedical device that can include a battery and that can be implanted to a user for a long period of time. In some examples, such pacemakers can, as a rule, be enclosed in welding-sealed titanium housings, or in other examples, multiple layers of the cover. New biomedical powering devices may present additional difficulties in terms of the shell, especially the shell of batteries. These new devices can be much smaller than existing biomedical devices, for example, an electronic contact lens or a tablet camera can be much smaller than a pacemaker. In such examples, the volume and area available for the shell can be significantly reduced. The advantage of limited volume may be that the quantities of materials and chemicals may be so small that they, by their nature, limit the potential impact on the user to a level below the safety limit.

A bicuspid approach, in particular, in the presence of hermetic sealing layers, can provide means to enhance biocompatibility. Each of the components of the double configuration can provide a significant barrier to the entry and exit of materials. In addition, using many of the hermetic sealing methods described herein, a battery can be formed that has excellent biocompatibility.

Contact lens skirts

In some examples, a preferred encapsulating material that can form an encapsulating layer in a biomedical device may include a silicone component. In the example, this encapsulating layer may form a contact lens lens skirt. The term "silicone-containing component" is understood to mean a component that contains at least one [-Si-O-] unit in the composition of the monomer, macromer or prepolymer. Preferably, the total content of Si and its associated O in the silicone-containing component is more than about 20% by weight, more preferably more than 30% by weight. of the total molecular weight of the silicone component. The silicone components used preferably contain polymerizable functional groups such as acrylate, methacrylate, acrylamide, methacrylamide, vinyl, N-vinyl lactam, N-vinyl amide and styryl functional groups.

In some examples, the ophthalmic lens skirt, also called the insert-encapsulating layer that surrounds the insert, can be made of standard hydrogel formulations for an ophthalmic lens. Examples of materials with characteristics that can provide an acceptable combination with a variety of insert materials may include materials of the narafilcon family (including narafilcon A and narafilcon B) and the family of etafilcon (including etafilcon A). Below is a more technical description of the nature of the materials according to the state of the art described in this document. The person skilled in the art will understand that other materials other than those described below also allow the formation of an acceptable shell or partial shell for sealed and sealed inserts, and they should be considered as consistent and included within the scope of the claims.

Suitable silicone components for the purposes of the present invention include compounds of formula I

Where

R1 is independently selected from monovalent reactive groups, monovalent alkyl groups or monovalent aryl groups, any of the above mentioned may additionally contain functional groups selected from hydroxy, amino, oxa, carboxy, alkylcarboxy, alkoxy, amido, carbamate, carbonate, halogen or combinations thereof ; and monovalent siloxane chains contain 1-100 Si-O repeating units and may additionally contain functional groups selected from alkyl, hydroxy, amino, oxa, carboxy, alkylcarboxy, alkoxy, amido, carbamate, halogen, and combinations thereof;

where b = 0-500, and it is assumed that, if b is different from 0, then b has a distribution, the mode of which is equal to the declared value;

wherein at least one R1 is a monovalent reactive group, and in some examples, from one to 3 R1 are monovalent reactive groups.

The term "monovalent reactive groups" as used herein refers to groups capable of free radical and / or cationic polymerization reactions. Typical but non-limiting examples of free radical reactive groups include (meth) acrylates, styryl, vinyls, vinyl ethers, C1-6 alkyl (meth) acrylates, (meth) acrylamides, C1-6 alkyl (meth) acrylamides, N-vinyl lactams, N-vinyl amides , C2-12 alkenyls, C2-12 alkenylphenyls, C2-12 alkenylnaphthyls, C2-6 alkenylphenyl-C1-6 alkyls, O-vinylcarbamates and O-vinylcarbonates. Non-limiting examples of cationic reactive groups include vinyl ester or epoxy groups, as well as mixtures thereof. In one embodiment, the free radical reactive groups contain (meth) acrylate, acryloxy, (meth) acrylamide, and mixtures thereof.

Suitable monovalent alkyl and aryl groups include unsubstituted monovalent C1-C16 alkyl groups, C6-C14 aryl groups, such as substituted and unsubstituted methyl, ethyl, propyl, butyl, 2-hydroxypropyl, propoxypropyl, polyethyleneoxypropyl, combinations thereof, and the like.

In one example, b is zero, one R1 is a monovalent reactive group, and at least 3 R1 is selected from monovalent alkyl groups having from 1 to 16 carbon atoms, and in another example from monovalent alkyl groups having from 1 to 6 atoms carbon. Non-limiting examples of silicone-containing components in this embodiment include 2-methyl-, 2-hydroxy-3- [3- [1,3,3,3-tetramethyl-1 - [(trimethylsilyl) oxy] disiloxany] propoxy] propyl ester (SiGMA),

2-hydroxy-3-methacryloxypropyloxypropyltris (trimethylsiloxy) silane,

3-methacryloxypropyl tris (trimethylsiloxy) silane (TRIS),

3-methacryloxypropylbis (trimethylsiloxy) methylsilane and

3-methacryloxypropylpentamethyldisiloxane.

In another example, b is from 2 to 20, from 3 to 15, or in some examples from 3 to 10; at least one terminal fragment of R1 is a monovalent reactive group, and the remaining R1 groups are selected from monovalent alkyl groups having from 1 to 16 carbon atoms, and in another embodiment from monovalent alkyl groups having from 1 to 6 carbon atoms. In yet another embodiment, b is from 3 to 15, one end of R1 is a monovalent reactive group, the other end of R1 is a monovalent alkyl group having from 1 to 6 carbon atoms, and the remaining R1 are monovalent alkyl groups having from 1 up to 3 carbon atoms. Non-limiting examples of silicone components of this embodiment include polydimethylsiloxane with end (mono- (2-hydroxy-3-methacryloxypropyl) -propyl-ester groups (molecular weight 400-1000)) (OH-mPDMS), polydimethylsiloxanes with end monomethacryloxypropyl group with the final mono-n-butyl group (molecular weight 800-1000), (mPDMS).

In another example, b is from 5 to 400 or from 10 to 300, both terminal R1 are monovalent reactive groups, and the remaining R1 are independently selected from monovalent alkyl groups having from 1 to 18 carbon atoms, which can have ether bonds between carbon and may additionally contain halogen.

In one example, where it is desirable to use silicone hydrogel lenses, the lenses of the present invention are made from a reaction mixture containing at least about 20 and preferably from about 20 to 70% by weight. silicone components based on the total weight of the reactive components of the monomer mixture from which the polymer is formed. In another embodiment, from one to four, R1 is a vinyl carbonate or carbamate of the formula:

Formula II

where Y is O-, S- or NH-;

R is hydrogen or methyl; d is 1, 2, 3 or 4; and q is 0 or 1.

Silicone-containing vinylcarbonate or vinylcarbamate monomers specifically include: 1,3-Bis [4- (vinyloxycarbonyloxy) but-1-yl] tetramethyl disiloxane; 3- (Vinyloxycarbonylthio) propyl- [tris (trimethylsiloxy) silane]; 3- [tris (trimethylsiloxy) silyl] propyllylcarbamate; 3- [Tris (trimethylsiloxy) silyl] propylvinylcarbamate; trimethylsilylethyl vinyl carbonate; trimethylsilylmethyl vinyl carbonate and

If biomedical devices with a modulus of elasticity less than about 200 are needed, only one R1 should be a monovalent reactive group, and no more than two of the other R1 should be monovalent siloxane groups.

Another class of silicone-containing components include polyurethane macromers with the following formulas:

Formula IV-VI

(* D * A * D * G) a * D * D * E1;

E (* D * G * D * A) a * D * G * D * E1 or;

E (* D * A * D * G) a * D * A * D * E1,

Where

D is an alkyl diradical, an alkyl cycloalkyl diradical, a cycloalkyl diradical, an aryl diradical or an alkylaryl diradical having from 6 to 30 carbon atoms,

G denotes an alkyl diradical, a cycloalkyl diradical, an alkyl cycloalkyl diradical, an aryl diradical or an alkylaryl diradical having from 1 to 40 carbon atoms which may contain ether, thioester or amine bonds in the main chain;

* means urethane or ureid bond;

a is at least 1;

A means a divalent polymeric radical of the formula:

Formula VII

R11 is independently an alkyl or fluoro-substituted alkyl group having from 1 to 10 carbon atoms, which may have ether bonds between carbon atoms; y is at least 1; and p provides a molecular weight of from 400 to 10,000; Each of E and E1 independently denotes a polymerized unsaturated organic radical represented by the formula:

Formula VIII

where R12 is hydrogen or methyl; R13 is hydrogen, an alkyl radical having from 1 to 6 carbon atoms, or a radical —CO — Y — R15, in which Y is —O—, Y — S— or —NH—; R14 is a bivalent radical having from 1 to 12 carbon atoms; X means -CO- or -OCO-; Z is -O- or -NH-; Ar means an aromatic radical having from 6 to 30 carbon atoms; w is from 0 to 6; x is 0 or 1; y is 0 or 1; and z is 0 or 1.

Preferably, the silicone component is a polyurethane macromer represented by the following formula:

Formula IX

wherein R16 is a diisocyanate biradical after removal of an isocyanate group, such as the isophorone diisocyanate biradical. Another acceptable silicone-containing macromer is a compound of formula X (where x + y is a number in the range from 10 to 30) obtained by reacting a fluoroether, a hydroxy-terminated polydimethylsiloxane, isophorone diisocyanate, and isocyanatoethylmethacrylate.

Formula X

Other silicone components suitable for use in the present invention include macromers containing polysiloxane, polyalkylene ether, diisocyanate, polyfluorocarbon, polyfluoroether and polysaccharide groups; polysiloxanes with a polar fluorinated graft or side group having a hydrogen atom attached to a terminal fluorinated carbon atom; hydrophilic siloxanil methacrylates containing ether and siloxanilic bonds, as well as cross-linkable monomers containing polyether and polysiloxanyl groups. In some examples, the polymer backbone may have zwitterions embedded in it. These zwitterions can exhibit charges of both polarities along the polymer chain when the material is in the presence of a solvent. The presence of zwitterions can improve the wettability of the polymerized material. In some examples, any of the above polysiloxanes can also be used as an encapsulating layer in the present invention.

Chemical deposition of metallic layers on battery sealing structures

The metallic coating is of great practical value in many applications, as non-limiting examples: for aesthetic purposes on jewelry or metal devices, to increase the corrosion resistance of industrial equipment or surfaces of devices / materials or even to increase the surface electrical conductivity. In a biocompatible power cell, the coating surrounding the battery body can be used to form a hermetic barrier to penetrate the material or exit the material. Numerous methods for applying a metal layer to a battery can be applied, but the basic premise may include coating or a layer of metallic material on the external surfaces of a battery. The metallic coating can be applied using many types of metals, including copper, nickel, platinum, rhodium and many others. Metal deposition may be the deposition of metals on many types of other materials, including, among others, other metals, semiconductors or plastics.

Typical examples of metal plating methods may include electrolytic and chemical deposition; both of which involve covering the material with a layer of metal. However, electrolytic deposition may include the use of induced electrical charge on the material to be coated, while chemical deposition may not include the use of electricity, but may involve a chemical reaction that results in the deposition of metal.

Electrolytic deposition may involve multiple steps to obtain the desired coating, a constant thickness of the applied material, and other properties required for a successful coating. In some examples, the element may first be thoroughly pretreated to ensure efficient deposition. The pretreatment steps may include, among others, polishing, masking, pickling, rinsing, steam scrubbing, rinsing, ultrasonic rinsing or electro-cleaning as non-limiting examples. In some examples, the pretreatment may allow the removal of oil, grease or other contaminants from the surface of the element to be coated.

After successful pretreatment, the object to be coated can be placed in a solution bath containing the metal in ionic form for deposit. As a rule, electrolytic deposition methods may involve the creation of a positive electrical charge in the solution bath and a negative electrical charge on the object to be coated. This difference in electrical charge can lead to the emergence of a force of electrical attraction between the metal particles in the solution bath and the object to be coated. This force of attraction can chemically change the ionic state and bind the metal particles from the solution bath to the object, covering its surface.

Depending on the composition of the deposited material and the solution bath, to ensure efficient deposition, certain conditions should be maintained, which include, among others, voltage, the pH level in the solution bath, the metal concentration in the solution, the duration of the coating and the ambient temperature. Correction of these conditions may allow changing various aspects of the coating, including, among others, the finishing of the resulting metal surface, the color of the deposited metal, the deposition rate or the thickness of the deposited metal. Other external conditions, such as air bubbles or impurities in the solution bath, can also affect the resulting coating; these disadvantages can be eliminated by shaking the bath or using carbon treatment baths as non-limiting examples. In some examples, it may be important to eliminate all causes of deficiencies on the surface to be coated on the biocompatible feed element; since such defects can reduce the effectiveness of the sealing layer.

In addition, various forms of post-processing may be required to ensure successful electrolytic deposition, including, among others, rinsing, steam scrubbing, thermal drying or other methods.

Chemical deposition may involve multiple stages to obtain the desired coating, ensuring a constant thickness of the applied material and other properties required for successful coating. Chemical deposition may have the same requirements for coating and sealing a biocompatible feed element as those discussed for electrolytic deposition. First, the element to be coated can be carefully pretreated to ensure efficient deposition. The pretreatment steps may include, among others, cleaning. Cleaning can help remove contaminants and / or debris from any previous processing steps of the object being coated, as well as oil, grease or other contamination from the surface of the element to be coated. Cleaning can be done with acids or other types of cleaning solutions; when choosing a proper cleaning solution, it may be important to consider which material or garbage should be removed, the temperature that is maintained for the cleaned element (and therefore the solution) during cleaning, the required concentration of cleaning solution, the amount of mechanical work of the person performing the cleaning, which can be required (shaking, etc.), as well as other possible aspects.

The pretreatment steps may also include etching, masking, rinsing, drying, and immersing the object to be coated in a solution of an activator for pre-treatment by dipping, as well as an activating solution as non-limiting examples. Etching may involve the use of chemical and / or mechanical means as non-limiting examples for etching a profile in a work item to be coated, which will act as a prescribed place for coating. The dipping pretreatment solution may contain ions that are common to the activating solution, which will prepare the work item for actual coating; this solution for pre-treatment by dipping can be, as a rule, made with the possibility of applying to the working element, and it is not washed off before adding to the activating solution. A dipping pretreatment solution may be less sensitive to metal ion contamination than a concomitant activating solution. The use of a solution for pretreatment by dipping provides many advantages, including in a non-restrictive sense, a result that is less expensive and allows the activating solution to be protected from being contaminated with metal ions in order to increase the efficiency of the process and to obtain better quality results.

After pretreatment by dipping, an activating solution may be applied to the working element. The activator may contain some ions held in a reduced state by other ions in solution; in practice, the reduced ions can be mechanically retained on the binding surface, which acts as a catalyst for a chemical reaction that will promote chemical precipitation. Although a sufficient layer of an activating solution on the surface of the working element is important to catalyze the chemical precipitation process, it is important to note that a too thick layer of activating solution can act as a barrier to the proper adhesion of the applied metal and should be avoided.

The pretreatment steps may also include the post-deactivation, or acceleration stage, as it is also commonly called. This stage can serve to ensure that the activating substances precipitated from the activating solution in the pretreatment stage by dipping are as “active” as possible before the actual chemical precipitation stage. This stage can facilitate the interaction of the activating substances with the solution for chemical precipitation at the stage of actual coating; this can not only reduce the time it takes to initiate a chemical precipitation reaction, but can also minimize the potential of activating substances that contaminate the chemical precipitation solution, increasing the quality of the resulting coating. If you skip this stage of post-activation, the activating solution precipitated on the work item may contain slightly adhered substances, which may contaminate the chemical precipitation solution and may delay the start of the chemical precipitation reaction. In some examples, postactivating solutions can be acidic and can remove metal oxides, which can form on the surfaces of working objects due to the rinsing stages between the activator and the postactivator; Although this process has a positive effect on the work item, the postactivator may become contaminated, and it may be necessary to replenish the solution bath when an excessive concentration of these metals or other contaminants appears in it.

After pretreatment, the work item can be immersed in a chemical bath containing the following possible ingredients as non-restrictive examples: metal salts (required for metal deposition), a reducing agent, alkaline hydroxide, chelating agents, stabilizers, bleaching agents and optionally wetting agents . The reducing substance and hydroxide ions can provide the reducing force needed to precipitate the metal contained in the solution bath. The precipitation reaction can be initiated using catalytic substances that can be deposited on the surface of the working object during the activator stage. The choice of a typical chemical precipitation bath may depend on several factors, including, among others, the temperature, the required coating rate, the required coating thickness and metal concentration (and, consequently, the repeatability of the deposition reaction for many working objects in one bath, although this repeatability as can be seen, it may also depend on many other factors).

Increase Mechanical Strength with Chemical Precipitation

In some examples, a desirable solution for increasing mechanical strength may involve chemical precipitation as a method for creating a conformal barrier coating. Principles of chemical deposition have been considered in this paper. During chemical deposition, a suitable metal layer can be applied to a conductive or non-conductive coating. For the deposition of metals, such as nickel, copper and tin, onto plastics surfaces, chemical precipitation baths have been developed. The chemically precipitated metal can then be further precipitated using chemical precipitation or electrolytic deposition using a wide range of metals, including nickel, copper, tin, gold, silver, cadmium and rhodium. In some cases, due to cost, corrosion, and / or mechanical problems, it may be desirable to apply a layered structure that includes more than one layer of electrolytic deposition.

The coating can be of any thickness and can mechanically strengthen the battery in addition to acting as a barrier. This mechanical enhancement can lead to the forced displacement of hydrogen outside the cell, reducing or eliminating the swelling due to the formation of hydrogen gas during corrosion of zinc. In order to avoid a short circuit between the battery terminals due to deposition, it may be necessary to mask one or both terminals using non-conductive material during the coating process.

In some examples, a layer can be formed by chemical precipitation, and chemical deposition and / or electrolytic deposition can be used to create a conformal copper coating on them of approximately 25 microns (1 mil). The coating application tape can be used to mask both terminals of these batteries during coating to avoid short-circuiting the batteries during processing of the deposited coating.

Then this tape can be removed from the terminals, after which the battery can be maintained at room temperature with a relative humidity of 50%.

Insulating halves of double-leaf configuration in the design of battery components

In some examples, the elements of the battery can be designed in such a way that they ensure the separation of the regions of the active chemical composition of the battery into segments with reliable sealing layers. In some examples, these sealing layers may be hermetic. Dividing the active components of a battery into hermetically sealed segments can have many advantages, and these segments can, as a rule, take a bivalve form. Bivalves with external components made of plastic, metal, glass or ceramic can form an ideal aspect of the structural configuration. In some examples, materials can be chosen in such a way that seals that are formed between materials can be considered “hermetic”, since the diffusion of molecules through this seal can be lower than the specification according to the test protocol for “seal type or type of method used to create a seal ". For example, electronic components, such as batteries, may have some air volume or some volume “equivalent to some air” inside them, and the tightness specification may refer to a seal that has a leak rate below a certain level at which 50% of the volume of the device is replaced. air taken outside the seal. A large bicuspid battery can be formed using one or more processes, which will be discussed in subsequent sections of this document, while a low leakage level can be measured to determine the degree of tightness of the sealing layer for a particular battery. In practice, small bivalve batteries or microbatteries, such as those described in this document, may in some examples have a volume of the order of 10 ⁻⁴ cm ³ . The ability of a leak detection device to measure a sufficiently low leakage rate to establish that the microbattery seal is “hermetic” may not be achievable for leakage detection methods currently used; However, the microbattery sealing layer may be referred to as hermetic, since similar processing and materials, when applied to a battery of coarse mold, result in a significantly low leakage rate sufficient to consider the sealing layer and materials to be "hermetic."

During the experiments, various materials and types of sealing layers were studied from the point of view of sealing aspects. The integrity of the sealing layer, as well as the integrity of the volume for the transfer of water molecules, can be characterized using the previously described WVTR indicator, which refers to the penetration of water vapor. Including, it is possible to measure the penetration of oxygen through a barrier or sealing layer. These measurements can be described as partly relative values, since the conditions in which a sealed battery may be located do not quite correlate with conditions during measurement. In some examples, WVTR tests can be carried out, for example, in a drying chamber, so that leak detection equipment can determine the change in water vapor due to penetration through the barrier. This is compared with the actual storage of the device in a biomedical device immersed, for example, in an aqueous solution. However, the characteristics of the films can be quantified under the conditions of the test in order to establish what can be applied in practice to the different materials used compared with their measurements during the tests. The following table presents examples of the results for different types of films and chemically applied / electrolytically deposited films. The first column provides a quantitative determination of oxygen penetration rates (OTR) and water vapor penetration rates (WVTR) for uncoated films and uncoated films with Si02 deposited. Then films of various thickness are applied. With a relative comparison, an uncoated film may have a WVTR of approximately 1300 more than a film when applied to approximately 63 microns of copper. (This may be the minimum value, since 0.01 is the lower limit of the instrument measurement). Thus, it is expected that the coating of a double-walled battery by chemical application can lead to a significant improvement in the hermetic properties of the battery design.

OTR, cm ³ / m ² / day WVTR g / m ² / day Uncoated film 5527 13.92 Uncoated + SiO _x 66,18 1,783 Copper (0.0003 inch) 1.65 0.123 Copper (0.0003 inch SiO _x ) 0.022 0.01 Copper (0.00063 inch) 0.012 0.01 Copper (0.00065 inch SiO _x ) 0.047 0.037 Tin (0.0006 inch) 545 0.155 Tin (0.0006 inch SiO _x ) 650 0.55 Tin (0.001 inch) 1,067 0,017 Tin (0.001 inch SiO _x ) 561 0.01

FIG. 2A1, 2A2, and 2A3 show the main examples of various types of bivalve batteries in cross section. The examples presented are located in the same plane; however, examples in the same plane may have similar bivalve configurations and are described in the following sections. FIG. 2A1 shows a basic example of a double-leaf battery 200 with a base body of insulating material divided into two “flaps”. Elements of the protrusions are included in the body of the bivalve configuration. In the example, two components that can be made of semiconductor or insulating materials form the upper half 211 of the bivalve configuration and the lower half 212 of the bivalve configuration, each of which may contain chemical substances 221 anodes and chemical substances 222 cathodes. In some examples, the halves of the bivalve configuration may themselves be surrounded by formed metal tubes that surround the material. In some examples, cathode chemicals 222 and anode chemicals 221 may be separated by separator 240. The separator may go in the center of the lower half 212 of the bivalve configuration until the battery structure closes at the place where it is adjacent to the bivalve half configuration. In some examples, such a configuration may be effective in physically separating the anode and cathode and preventing leakage in the upper and lower parts of the separator. To create a working battery, battery contacts that are not shown in the cross-sectional drawing must be electrically isolated from each other, since electrical connection will lead to depletion of the chemical composition of the battery. In the first example, a sealing layer 230 may be formed between the included elements of the projections of the two halves of the double-leaf structure.

FIG. 2A2 shows an example of a modification of the basic configuration, with the double configuration represented with prominent protrusions 201. In some examples, a large sealing surface may be formed by prominent protrusions and may form a sealing layer 230A of excellent configuration. In some examples, a significant amount of protruding part can be used to form large sealing layers.

FIG. 2A3 shows an example of a modification of the basic configuration, with the upper half of the bivalve configuration 211 being a flat flap, and the lower half of the 212 folding configuration - a flap with a hollow. The peripheral edge of the flat sash can form the equivalent of a member of a protrusion of a sash with a recess and can abut and seal the protrusion of a sash with a recess.

In the main examples in FIG. 2A1, 2A2, and 2A3 halves of the bivalve configuration, made of insulating or semiconductor materials, electrically separate the anode and cathode. In some other more complex configurations of double-leaf batteries, the metal flap can be combined with an insulating flap. In some other configurations, two metal flaps can be made with an insulating flap in between. The bicuspid configuration, made of an insulating material, can be a solid insulating material with a crystalline structure or plastic, which can also be an insulating material.

As shown in the various examples, at least one sealing layer may be formed between the halves of the bivalve configuration. In the case of more complex structures, a second sealing layer may be located between the metal halves of the bicuspid configuration and the intermediate insulating material. The halves of the bivalve configuration can be a physical structure, which itself serves to hold the material inside the battery and as part of a diffusion barrier to prevent chemicals from moving inside or out of the battery. In earlier discussions, a description was given of various types of sealing layers, including hermetic sealing layers, as well as methods of their formation. Examples of the sealing layer 230 include metal-ceramic or metal-glass sealing layers, combinations of ceramics-ceramics, ceramics-glass, glass-glass, plastic-ceramics, plastic-glass and others.

FIG. 2B and 2C show alternative projections of the upper and lower halves of the bivalve configurations of batteries 200, 201 and 202, which are shown in FIG. 2A1, 2A2 and 2A3. FIG. 2B shows a top down view of the lower half 212 of a double-wing battery 200, which can be hermetically connected to the upper half 211. The lower half 212 is represented without the corresponding anode and cathode chemicals, and thus shows the cavity occupied by these chemicals. FIG. 2C is a bottom-up view of the upper half 211.

The lower half of a bivalve battery 212 may include an anode region 231 or an anode cavity. The cavity may include an electrical connection 262, which electrically connects the chemical composition of the anode with the anode contact 261 of the battery. The lower half 212 may also include a cathode region 232 or a cathode cavity. The cathode cavity may include an electrical connection 272, which electrically connects the chemical composition of the cathode with the cathode contact 271. In the example presented, the cathode contact 271 and the anode contact 261 are located in areas of the same half of the bivalve configuration. In some other examples, each flap may have one contact with the compound with the appropriate chemical composition.

When the two halves of the double-wing configuration are brought together, the upper flap can be hermetically attached to the lower flap at the junction between them. FIG. 2A1 shows a sealing layer 230. As shown in FIG. 2B, the sealing layer may essentially be a protrusion of a bivalve material. The inner protrusion 235 of the lower half 212 may fit and be in contact with the inner protrusion 237 of the upper half 211 of the bivalvia configuration. External protrusions 234 and 235 are described in more detail below. Different types of sealing layers can be formed on these protrusions depending on the material of the double leaflet configuration. In some examples of ceramic or semiconductor halves, an S-bonded sealing layer or soldered sealing layers can be formed on metal layers applied by vapor deposition on halves of a bivalve configuration. FIG. 2D shows a close-up view of the area of the sealing layer for the outer lip 234 of the lower half 212 with a large-scale view. The outer protrusion 236 of the upper half 211 may interact with the corresponding outer protrusion 234 of the lower half 212, and the large scale view shows the area where the sealing layer is formed.

FIG. 2E, an example of a lateral projection of the region of the sealing layer between the lower half 212 and the upper half 211 of the bivalve battery 200 shown in FIG. 2A1, as well as an example of layers related to the sealing layer, prior to the activation of Nanofoil® material. It is obvious that in similar situations it is possible to obtain double-wing configurations depicted in FIG. 2A2 and 2A3. On the upper half 211 of the bicuspid configuration and the second half 212 of the bicuspid configuration, a pre-moistened solder layer can be applied on each side for the first solder layer 238 and the second solder layer 239. Material 250 Nanofoil® can be placed between these two solder layers. When activated, Nanofoil® material can locally melt solder layers and form sealing layer 230. The illustration shows a butt joint, however many other types of joints can be used, including overlapping, slotted and other types of joints, where Nanofoil® can be placed between two surfaces intended for sealing, on the surfaces of which a solder layer is applied. In other examples, the structure depicted in FIG. 2E may be formed by applying a metallic layer on the protrusions of the halves of a bivalve configuration in areas intended for sealing (for example, protrusions 234-237). Metal surfaces can be used to solder metals with soft or hard solder to form a hermetic sealing layer.

In other examples, the bicuspid configuration may be made of metal flaps, and between the metal flaps an intermediate flap made of ceramic or other insulating material will be located as the electrically insulating flap. In such examples, each metal flap can form a sealing layer with an insulating flap using a structure similar to that shown in FIG. 2E.

In other additional examples, the leaflets of the bicuspid configuration may be made of plastic materials. The plastic material may include applied or attached metal areas for battery electrodes, however, sealing layers at the edges of the halves of the bivalve configuration can be sealed with adhesives or by fusing using techniques such as ultrasonic soldering or laser soldering.

Numerous materials can be used as photosensitive sealing substances that may be sensitive to light or to UV light. Any sealant known in the art may be used, but non-limiting examples of branded adhesives include: DELO Kaitobond OB614, DELO Kaitobond OM VE 115261, Delo LP 424, DELO Photobond LP VE526279, Dymax 1121-420, Dymax 1121-7401, Dymax 1128A -7401, EMI 10590, EMI optocast 3553, Epotek 301, Epotek 301-2, Epotek OG142-112, Epotek OG142-95, Epotek OG603, Henkel Loctite 3341, Henkel Loctite 3922, Henkel Loctite 3942, Henkel Loctite 5055, Henkel Loctite M -11FL, Momentive RTV 615, Momentive UVLSR 2060, Momentive UVLSR 7070, Norland Optical Adhesive 61, Norland Optical Adhesive 68, orland Optical Adhesive 86, NuSil MED-6010, Nusil MED-6400, Permabond UV 632, Tangent 40093, Tangent 7090 and Threebond 30Y-951.

FIG. 3A, an alternative example of a bivalve battery 300 can be seen. In this example, two sealing components, the upper component 310 of the bivalve configuration and the lower component 330 of the bivalve configuration, can form a housing that surrounds the battery material. As examples, not having a restrictive nature, the components can be made of silicon or ceramic materials. Chemicals 312 of the anode may be located within the upper component 310 of the bicuspid configuration. And cathode chemicals 340 may be located inside the lower component 330 of the bicuspid configuration. In this example, the dimensions of the upper component 310 and the lower component 330 may be identical, therefore, when hermetically sealed to each other, they form a double battery 300, which is geometrically symmetrical along the horizontal axis formed by the sealing layer. In other practical examples, the volume of anode chemical in the upper component 310 of the bivalve configuration may be less than the volume of the cathode chemical in the lower component 330 of the bivalve configuration. Cathode chemicals 340 and anode chemicals 312 may be separated by separator 320. Battery contacts must be isolated from each other to create a functionalized battery, since electrically connecting them can lead to battery discharge. The upper and lower components of the bicuspid configuration can be made of various insulating materials, for example, among others, ceramics, glass and plastic. The sealing layer can be one of the combinations of ceramic-ceramic, ceramic-glass, glass-glass, as described earlier, which can form a sealed sealing layer.

FIG. 3B is an illustration of an example of the lower half 330 of a bicuspid configuration, and FIG. 3C is an example of the upper half 310 of a bicuspid configuration. The configuration of an example double-walled battery suggests a single-cell battery with an external electrical contact on each flap. The lower half of the bivalve configuration contains a single cavity 332 for various battery chemicals. This cavity is surrounded by a protrusion 331. An electrical connection 333 connects the region of the cavity with an exemplary cathode contact 334. As shown in FIG. 3C, the upper half of the bicuspid configuration may include a single cavity for anode chemicals 312, and in some other examples, an upper plate. The electrical connection 313 may connect the battery anode to the anode contact 314. A protrusion 311 of the upper half of the double configuration overlaps the projection 331 of the lower half of the double configuration when the upper half is located above the lower.

FIG. 3D and 3E show another example of a double-leaved battery shown in FIG. 3A, with numerous battery cells, as well as anodic and cathodic contacts, shown on one leaf of a bivalve configuration that is not covered by the components of the lower half of the bivalve configuration. The lower half 330 of the bivalve configuration contains two cavities 351 and 352, with the electrical contact 353 placed between these elements. The two cavities will function if the chemicals from the two cavities are mirrored relative to each other; for example, if in cavity 352 the anode chemicals will be under the cathode chemicals, and in cavity 351 the cathode chemicals will be under the anode chemicals. In other examples, the chemicals may be opposite in location. As shown in FIG. 3E, the two cavities 358 and 359 may include electrical connections 354 and 355 that connect each of the two cavities to contacts 356 and 357. The projections 311 and 331 of the upper half 310 of the double leaf configuration and the lower half 330 of the double leaf configuration can be used to form a hermetic sealing layer as described in this document.

FIG. 3F and 3G again provides a similar example of the configuration of the double-walled battery shown in FIG. 3D and 3E, with numerous elements and open contacts in one half of the double leaflet configuration. The lower half 330 of the bivalve configuration contains two cavities 363 and 364, with the electrical contact 365 placed between these elements. The two cavities will function if the chemicals from the two cavities are mirrored relative to each other; for example, if in the cavity 363 the anode chemicals will be under the cathode chemicals, and in the cavity 364 the cathode chemicals will be under the anode chemicals. In other examples, the chemicals may be opposite in location. As shown in FIG. 3G for the upper half 310 of the bicuspid configuration, the two cavities 361 and 362 may include electrical connections 366 and 367, which connect each of the two cavities with contacts 368 and 369. However, the half of the bivalve configuration of this example can be made of a semiconductor material in such a way that electrical connections 366 and 367 can be formed by adding a significant amount of impurities to these areas of semiconductor material in the halves of the bivalve configuration. Therefore, it is possible to make electrical contact with the external contact through half the bivalve configuration in such a way that there is no gap in the sealing layer. The tabs 311 and 331 of the upper half 310 of the bicuspid configuration and the lower half 330 of the bicuspid configuration can be used to form a hermetic sealing layer in the manner described in this document. In addition, these sealing layers can form an extremely tight hermetic sealing layer due to the lack of physical electrical contact between the sealing surfaces in order to make electrical contact from the chemical composition of the battery to the contact areas.

FIG. 3H and 3I show an example in which the double configuration has the shape of a full circle. The lower half 330 of the bivalve configuration includes a single cavity 371 around the entire circumference with an electrical contact 374. The illustrated case refers to the semiconductor half of the bivalve configuration with an electrical contact in the form of a semiconductor casement with a large number of impurities. In some examples, the semiconductor material may be an inorganic semiconductor, such as silicon, where atomic impurities, such as phosphorus and boron, can change conductivity. In some other examples, the semiconductor material may be organic semiconductors in which molecular impurities can change the conductivity of individual portions and provide electrical contact. Numerous organic semiconductor systems with impurities can be used; However, as a non-limiting example, poly (3-hexylthiophene) (P3HT) with 2,3,5,6-tetrafluoro-7,7,8,8-tetracyanoquinodimethane (TFTCHND) can be used in the polymer matrix. An extensive area of an organic semiconductor with an admixture can be coated with a metal film to form a contact pad. In other examples, the insulating or plastic bicuspid configuration may include a metal contact that penetrates through half the bicuspid configuration with a good hermetic sealing layer. The cavity may contain a chemical composition of the cathode and, possibly, a separator. The upper half 310 of the bicuspid configuration may include a cavity 370 for the chemical composition of the anode, which may be, for example, an anode electrolytically applied to the bicuspid sash. In addition, the upper flap of the bivalve configuration may include a diffusion silicon contact area 375. The protrusions 311 and 331 of the upper half 310 of the bivalve configuration and the lower half 330 of the bivalve configuration can be used to form hermetic sealing layers in the manner described in this document. Since the shape of the illustrated battery is a complete circle, the protrusion 311A, insulated from the projection of the upper half of the bivalve configuration, and protrusion 331A insulated from the projection of the lower half of the bivalve configuration, are present. The protrusions 311A and 331A can form a sealing layer in a similar manner of sealing as the outer projections. These sealing layers can form an extremely tight hermetic sealing layer due to the absence of physical electrical contact between the sealing surfaces in order to make electrical contact from the chemical composition of the battery to the contact areas.

Of the examples of components of the bivalve configuration made of insulating materials, this document provides examples of the electrical connection that can be formed by pulling the electrode lead through the soldering area to the contact pad. In other examples, impurities may be added to the semiconductor components of the bivalve configuration to provide electrical contact that will pass through the casing of the bivalve configuration. Other examples may include conductive junctions that cut into insulating materials and then filled with conductive materials. The placement of conductive transition materials can be done in such a way that the transition sealing layer will support the hermetic sealing layer.

In some examples, an electrolyte may be injected into the bivalve battery through the filler hole. The battery can be drawn under vacuum to remove gases through the filler hole, and through this hole the electrolyte can enter the body of the bivalve configuration. Thereafter, a sealing layer may be formed by introducing an adhesive or polymerizable material through the filler hole. In some examples, the filling of the filler hole may be carried out before applying a metallic coating on a bivalve battery to improve the hermetic sealing layer.

Metal halves of double-leaf configuration in the design of battery components

FIG. 4 shows an example of a composite bivalve battery. In the example, the metallic upper half 410 of the bivalve configuration and the metallic lower half 470 of the bivalve configuration may contain battery cells, as previously discussed for other examples of the bivalve configuration. Since the metal halves of the double-leaf configuration will lead to the closure of the battery cell, if they are connected to each other, an insulating intermediate flap 440 is placed between them, which is connected to the sealing layer 430 and the sealing layer 450. as described in this document. The battery may contain internal support members 415 for holding the components in place during assembly before the sealing sealing layers are formed. Similarly, the anode 420 may be formed on the upper half 410 of a bivalve configuration, and the cathode 460 may be placed or formed on the lower half 470 of a bivalve configuration, which can already be connected to an insulating intermediate sash 440.

Plastic halves of double-leaf configuration in the design of battery components

FIG. 5A shows an example of a plastic double-leaf configuration of a biocompatible energy supply element 500 in cross section. A central separator 531, an anode 530, an anode current collector 571, a cathode 532 and a cathode current collector 573 can be placed in the lower half of the double-leaf configuration 520. by melting plastic elements to form a dense sealing layer on the contact surface. The sealing layer 541 is presented with a “through” view to show that the bicuspid projections can be fused together to form a sealing layer along the contact surface of the protrusions. A sealed plastic double-leaf battery can be made even more airtight by covering a significant part of the plastic battery's case with a metal film formed by chemical deposition followed by electrolytic deposition.

In other examples, the plastic blank that is used to form the flaps of the bicuspid configuration can be made of a composite plastic material, such as polymer, metal film, polymer multilayer primary films. Other examples are also possible in which a metal film is formed within the flaps of the bivalve configuration or is applied to the flaps of the bivalve configuration before adding other elements. Similarly, a chemically applied / electrolytically deposited film can be added to bivalve configurations that already contain a metal film inside or outside.

As shown in FIG. 5B, a plastic double-leaf battery can be encapsulated with metal films to improve the tightness of the sealing layer of the outer layers of the double-leaf configuration. The bicuspid surface can be cleaned and processed by pre-immersion in an acidic wash solution to remove contamination, such as residual slurry. Other washing and cleaning options may include a RCA cleaner, a peroxide-based cleaner like SC1 and SC2, hydrofluoric acid, sulfuric acid, and combinations of acids. The accelerator or sensitizer may include specialized formulations, for example, a Type C solution manufactured by Transene. Then an activator can be used for surface treatment. As a non-limiting example, a “D-type” solution of the Transcene Company can be used. FIG. 5B shows the result of such processing in the form of a layer 560 on a fully formed biocompatible energy supply element 500 shown in FIG. 5B.

Then the pre-treated surface can be immersed in chemical precipitation baths, in this example, copper. The pre-treated and activated battery body can now be immersed in a Transene wash-wash mixture for chemical precipitation with Type A and Type B copper at an elevated temperature of approximately 40 ° C for some time to form a coating of several microns. The resulting deposition is shown as layer 561. In some examples, the subsequent washing of the surface with acids can be performed to harden the surface.

In some examples, a thicker coating layer, for example 10 microns or more microns thick, may be applied to a chemically deposited layer using a bath for electrolytic deposition of copper. The resulting copper layer is shown as layer 562. In some examples, rhodium can be followed by electrolytically deposited copper layer by electrolytic deposition as layer 563. Rhodium can stabilize and protect the surface of copper; therefore, in some examples, a thin layer may be applied as an upper surface.

If the entire battery cell is covered with a layer of copper, the two battery contacts will be shorted and the battery will become non-functional. Therefore, one or both contacts of the battery can be protected before coating to prevent coating from forming around the contacts and insulating the contacts. FIG. 5C, an example of a top view of a plastic double-leaf battery before electrolytic deposition is shown for the battery shown in FIG. 5A, with a cathode contact 574, a dotted line to indicate the element hidden behind the protective film 575, and an anode contact 572. The electrical connection layers can be used to form an electrical connection between the anodes and the cathodes of the battery through their current leads with corresponding contact pads. A protective film 575, for example, an insulating tape, may be placed around the cathode contact, the cathode current lead and the electrical connection layer associated with it. The remaining surface of the battery can be coated with chemically applied / electrolytically deposited layers, as shown in FIG. 5B. The fact that the contact area may have a surface of an uncoated multilayer structure may not be a problem for sealing a battery. In some examples, the contacts can be made sufficiently long, so that near the contact there is a relatively large seal. On the other hand, during operation of a primary battery, gases may form, for example, gaseous hydrogen. The presence of an area around one or more contacts, which is also not sealed, may be preferable, since in this case a channel may be created through which the generated gases can slowly dissipate.

FIG. 5D shows an example of a plastic double-leaf configuration after applying an insulating tape or other protective film. The applied film 576 can cover the entire structure, except for the area covered by the protective film. In the present example, the anodic contact area, including the anodic contact 572 and the anode current collector 571, is coated with a chemically applied / electrolytically deposited film. In turn, the cathode contact 574 and the cathode current lead 573 remain uncovered. In some examples, the coating of the anode contacts may also be missing. Whereas this example illustrates plating by chemical reduction, similarly, in other examples, other materials, such as insulators, glass, etc., can also be processed and coated by chemical reduction.

FIG. 6A shows bivalve batteries of irregular shape with non-rectangular cross sections. The folding configuration may have various other irregular shapes. In some examples, an irregularly shaped plastic double-leaf construction may be extruded or pressed into a mold defined by a casting mold. FIG. 6A, an irregular shape with such a cross section can be made to better fit the shape of the standard contact lens space. The lower half of the bicuspid configuration 620 may slide from the center of the lens towards the outer portions of the contact lens into which the battery can be embedded. In some examples, the lower half 620 of the bicuspid configuration may be filled with cathode chemicals 630. The second half of the bivalve configuration, the upper half of 610, can be adapted to conform to regions 611 of the inner and outer protrusions along which the bivalve configuration can be sealed. In some examples, sealing may be performed by ultrasonic soldering. The upper half 610 of a bivalve configuration may include a separator 631, as well as the chemical composition of the 632 anode. The bicuspid structure can be filled with electrolyte before or after sealing, and a vacuum filling technique can be applied to the filling hole when filling occurs after sealing. In some examples, other types of electrolytes can be used for different concepts of the bicuspid configuration, for example, polymer electrolytes, as described earlier.

FIG. 6B shows an example of a plastic double battery. The upper half 610 of the bicuspid configuration and the lower half 620 of the bicuspid configuration are connected by a dense molten edge 640 of the sealing layer in the areas of the projections of the flaps of the bivalve configuration. Melting areas of the protrusions of the valves of the bicuspid configuration for the formation of dense molten sealing layers can be carried out using a variety of techniques. FIG. 6C and 6D show a top down view of examples of the lower half of the bivalve configuration (Fig. 6C) and the upper half of the bivalve configuration (Fig. 6D). The irregular shape shown in cross section in FIG. 6A, can be seen in the areas of double-walled batteries that are located inside different cavities in some examples. The bottom half 620 of the bicuspid configuration shown in FIG. 6C includes cavities 651 and 652 with such a cross-sectional shape. In addition, the lower half 620 of the bicuspid configuration shown in FIG. 6C may comprise protrusions 661 and internal electrical connections 653. In addition, the upper half 610 of the bicuspid configuration shown in FIG. 6D may include protrusions 611, cavities 658 and 659, electrical connections 654 and 655, and contacts 656 and 657, which have a similar geometric arrangement, as in the other examples of bivalve batteries, which have been described previously.

A method of manufacturing double-walled batteries

FIG. 7 is a flowchart 700 with examples of the steps of a method for manufacturing a bivalve battery from an insulating sealing material. Given the bivalve battery configuration, certain steps of the method, such as, inter alia, the application of components critical to the chemical composition of the battery, may extend to different processes for manufacturing bivalve batteries with different sealing materials; on the other hand, the steps of the method of manufacturing double-walled batteries with different sealing materials may also differ significantly, for example, with regard to precise sealing methods for sealing sealing components. First, step 702 involves obtaining a set of halves of a bivalve configuration made of an insulating material. These halves are the sealing components, which are essentially used to turn on and seal the bivalve battery, and can serve as the main components for the manufacture of the battery. At steps 704 and 706, additional method steps are proposed; after receiving the halves made of an insulating material, they can be additionally coated on the inside with vapor deposition film to ensure conductivity (step 704) or additionally cover the protrusions with a metal film for sealing (step 706). As described earlier in this document, these steps can serve as pre-activation steps that will contribute to the formation of insulator-insulator sealing layers, and can also occur separately or simultaneously. Thereafter, at step 708, conductive paths may be formed in the halves of the bivalve configuration. These tracks can be used to electrically connect important functional components of a battery’s chemical composition, to identify and connect battery contacts, or for other purposes that were described earlier in this document. Next, at step 710, an anode can be placed on one of the halves of the double configuration, after which, at step 712, a cathode can be placed on one of the halves of the double configuration. As described earlier in the previous sections, of all the different variants of the battery can be manufactured in a co-facial and coplanar configuration. In a cofacial configuration, half of the bivalve configuration on which the anode is placed may differ from half of the bivalve configuration on which the cathode is placed. However, with a coplanar configuration, since the anode and cathode are in the same plane, they can be placed on the same half of the bivalve configuration. With a coplanar configuration, the second flap of the double-wing configuration can perform the function of sealing and sealing. The anode and cathode placed in these stages may have an arrangement that is properly connected to the previously described conductive paths of step 708. Next, at step 714, a separator may be superimposed on one or both halves of the two-fold configuration; This applied or installed separation film can be used to physically and / or electrically separate the components of the anode and cathode from each other, as previously described in this document. At step 716, an electrolyte may be placed in each or at least one of the halves of the bivalve configuration filled with an anode and cathode; As previously described in this document, the electrolyte can play a key role in the chemical composition of the battery and provide ion transfer, through which the potential difference is established, which ensures the functioning of the battery. Subsequently, in step 718, the two halves of the bivalve configuration may be joined together, and a sealing layer may be formed between the projections of these halves of the bivalve configuration. Moreover, in additional step 720, at least the surface areas of the halves of the bivalve configuration can be further sealed by chemical deposition and / or electrolytic deposition. The above pre-activation steps can play a key role in the activation and formation of the sealing layer in steps 718 and 720. As an additional non-limiting example, the formation of the sealing layer can also be carried out using a Nanofoil® blank that can be positioned over the sealing area. After activation, the Nanofoil® material will melt the solder and form a soldered, airtight joint. In some examples, other forms of an insulator-insulator seal layer may be formed in the manner previously described herein.

FIG. 8 is a flowchart 800 with examples of the steps of a method for manufacturing a bivalve battery from a plastic sealing material. First, step 802 involves obtaining a set of halves of a bivalve configuration made of plastic material. These halves are sealing components, which are essentially used to turn on and seal a double-walled battery, and can be considered as the main components for the manufacture of a battery. At steps 804 and 806, additional method steps are proposed; after receiving the halves made of plastic material, they can be additionally coated on the inside with vapor deposition film to ensure conductivity (step 804) or additionally cover the projections and surfaces with a metal film to connect the inside and outside of the battery (step 806). As already described in this document, these steps can also serve as pre-activation steps in areas of the bivalve configuration, which will contribute to the formation of sealing layers, and can also occur separately or simultaneously. Thereafter, at step 808, conductive paths may be formed in the halves of the double-leaf configuration. These tracks can be used to electrically connect important functional components of a battery’s chemical composition, to identify and connect battery contacts, or for other purposes that were described earlier in this document. Next, at step 810, an anode can be placed on one of the halves of the double configuration, after which, at step 812, a cathode can be placed on one of the halves of the double configuration. As described earlier in the previous sections, of all the different variants of the battery can be manufactured in a co-facial and coplanar configuration. In a cofacial configuration, half of the bivalve configuration on which the anode is placed may differ from half of the bivalve configuration on which the cathode is placed. However, with a coplanar configuration, since the anode and cathode are in the same plane, they can be placed on the same half of the bivalve configuration. With a coplanar configuration, the second flap of the double-wing configuration can perform the function of sealing and sealing. The anode and cathode placed in these steps may be arranged in such a way that they are properly connected to the previously described conductive paths of step 808. Next, at step 814, a release film may be applied to one or both halves of the double leaflet configuration; This release film can be used to physically and / or electrically separate anode and cathode components from each other, as previously described in this document. At step 816, in each or at least one of the halves of the bivalve configuration filled with an anode and cathode, an electrolyte can be placed; As previously described in this document, the electrolyte can play a key role in the chemical composition of the battery and provide ion transfer, through which the potential difference is established, which ensures the functioning of the battery. Subsequently, at step 818, the two halves of the bivalve configuration can be joined together, and a molten sealing layer can be formed between the projections of these halves of the bivalve configuration. Moreover, at step 820, at least the surface areas of the halves of the bivalve configuration can be sealed by chemical deposition and / or electrolytic deposition. The above pre-activation steps may play a key role in activating and forming the sealing layer in steps 818 and 820. In some examples, other forms of plastic-plastic sealing layer may be formed in the manner previously described in this document. As previously discussed, various processing examples may be used in addition to the steps described in FIG. 8, or they may replace some of the exemplary processing steps.

FIG. 9 is a flowchart 900 with examples of the steps of a method for manufacturing a bivalve battery from a metallic sealing material with an intermediate partition door. First, step 902 involves obtaining a set of halves of a bivalve configuration made of a metallic material. These halves are sealing components that are essentially used to turn on and seal a double-walled battery, and can be considered as major components for the manufacture of a battery. At stages 904, 906 and 908, additional steps are proposed; after receiving the halves made of plastic material, they can be additionally coated with an inner and / or outer side to provide insulating properties or additionally apply an insulating coating on the protrusions (step 906). Since all surfaces and protrusions of the metal sealing component can be completely made of a conductive material, these steps can play an important role in limiting the conductive capacity in certain areas to prevent short circuits and other problems that prevent the proper operation of the bivalve battery. Thereafter, at step 908, conductive paths may be formed in the halves of the bivalve configuration; in some cases, after the application of an insulating coating, it may be necessary to add additional conductive paths later to reconnect the conductive portions of the metallic sealing material, which were insulated from each other when applied. These tracks can be used to electrically connect important functional components of a battery’s chemical composition, to identify and connect battery contacts, or for other purposes that were described earlier in this document. Next, at step 910, an anode can be placed on one of the halves of the double-wing configuration, after which, at step 912, a cathode can be placed on one of the halves of the double-wing configuration. As described earlier in the previous sections, of all the different variants of the battery can be manufactured in a co-facial and coplanar configuration. In a cofacial configuration, half of the bivalve configuration on which the anode is placed may differ from half of the bivalve configuration on which the cathode is placed. However, with a coplanar configuration, since the anode and cathode are in the same plane, they can be placed on the same half of the bivalve configuration. With a coplanar configuration, the second flap of the double-wing configuration can perform the function of sealing and sealing. The anode and cathode placed in these steps may have an arrangement that is properly connected to the previously described conductive paths of step 908. Next, in step 914, a release film may be applied to one or both halves of the bivalve configuration; This release film can be used to physically and / or electrically separate anode and cathode components from each other, as previously described in this document. At step 916, an electrolyte may be placed in each or at least one of the halves of the bivalve configuration filled with an anode and cathode; As previously described in this document, the electrolyte can play a key role in the chemical composition of the battery and provide ion transfer, through which the potential difference is established, which ensures the functioning of the battery. Subsequently, in step 918, the two halves of the bivalve configuration can be joined together by means of an intermediate insulating flap, and a sealing layer can be formed between the projections of these halves of the bivalve configuration and the projections of the intermediate flap. Moreover, in additional step 920, at least the surface areas of the halves of the bivalve configuration can be further sealed by chemical deposition and / or electrolytic deposition. The above pre-activation steps can be used to activate and form the sealing layer in steps 918 and 920.

FIG. 10 is a flowchart 1000 with examples of the steps of a method for manufacturing a bivalve battery of a semiconductor sealing material. First, step 1002 involves obtaining a set of halves of a bivalve configuration made of a semiconductor material. These halves are the sealing components, which are essentially used to turn on and seal the bivalve battery, and can serve as the main components for the manufacture of the battery. In some examples, the bivalve material can be an inorganic semiconductor, such as, for example, silicon, and in other examples organic semiconductor material can be used. 1004 is an optional step; after receiving the halves made of semiconductor material, they can be coated on the inside and / or the outside to provide insulating properties. At step 1006, impurities may be added to the semiconductor material of the halves of the bivalve configuration to substantially increase the conductivity of the material. In this regard, the contact areas of the battery can be formed without any sealing layers. Thereafter, at step 1008, conductive paths may be formed in the halves of the bivalve configuration. These tracks can be used to electrically connect important functional components of the chemical composition of a battery, to identify and improve areas of contact of the battery with impurities, or for other purposes that were described earlier in this document. Next, at step 1010, an anode can be placed on one of the halves of the bivalve configuration, and then at step 1012, a cathode can be placed on the other half of the bivalve configuration. The anode and cathode placed in these steps may be arranged in such a way that they are properly connected to the previously described conductive paths of step 1008. Next, at step 1014, a release film may be placed on one or both halves of the double leaflet configuration; This coating or release film can be used to physically and / or electrically separate the components of the anode and cathode from each other, as previously described in this document. At step 1016, an electrolyte may be placed in each or at least one of the halves of the bivalve configuration filled with an anode and cathode; As previously described in this document, the electrolyte can play a key role in the chemical composition of the battery and provide ion transfer, through which the potential difference is established, which ensures the functioning of the battery. Subsequently, at step 1018, the two halves of the bivalve configuration may be joined together, and a sealing layer may be formed between the projections of these halves of the bivalve configuration. In addition, in particular for examples of the halves of the bivalve configuration made of organic semiconductor material, at step 1020, at least the surface areas of the halves of the bivalve configuration can be sealed by chemical deposition and / or electrolytic deposition. The above pre-activation steps may play a key role in the activation and formation of the sealing layer in steps 1018 and 1020. In some examples, other forms of metal-to-metal sealing layer may be formed in the manner previously described in this document.

Biocompatible batteries can be used in biocompatible devices, such as, for example, implantable electronic devices, such as pacemakers and energy collection micro devices, electronic tablets for monitoring and / or testing biological function, surgical devices with active components, ophthalmic devices, micropumps, defibrillators, stents etc.

Concrete examples are described to illustrate embodiments of a cathode mixture for use in biocompatible batteries. These examples are intended for the purpose of illustration and are in no way intended to limit the scope of the claims. Accordingly, the description is intended to cover all examples that may be obvious to those skilled in the art.

Claims (108)

1. Biomedical device containing: electroactive component; battery containing: anode current lead; cathode current lead; anode; cathode; a bivalve configuration encapsulating an anode and a cathode having a first hole for the anode current lead, a second hole for the cathode current lead and a tight seal between the upper half of the bivalve configuration and the lower half of the bivalve configuration a metal coating covering at least a portion of the outer surface of the upper half of the bivalve configuration and the lower half of the bivalve configuration, with the metal coating applied by chemical reduction; and the first biocompatible encapsulating layer, the first biocompatible encapsulating layer encapsulates at least an electroactive component and a battery. 2. A double battery containing: an anode current lead, the anode current lead being the first metal film in the upper half of the bivalve configuration; the anode, and the chemical structure of the anode is contained within the upper half of the bivalve configuration or deposited on it; a cathode current lead, with the cathode current lead consisting of a second metal film on the lower half of the bivalve configuration; the cathode, and the chemical structure of the cathode is contained within the lower half of the bivalve configuration or deposited on it; and wherein the upper half of the bivalve configuration and the lower half of the bivalve configuration are made of one or more of ceramic, glass or plastic materials, and wherein a seal is formed between the protrusions of the upper half of the bivalve configuration and the lower half of the bivalve configuration. 3. The bicuspid battery according to claim 2, wherein the sealing material disposed between the protrusions of the upper half of the bivalve configuration and the lower half of the bivalve configuration contains an epoxy adhesive. 4. The bicuspid battery according to claim 2, wherein the sealing material disposed between the protrusions of the upper half of the bivalve configuration and the lower half of the bivalve configuration comprises solder. 5. The bicuspid battery according to claim 4, wherein the solder comprises titanium to improve adhesion to the ceramic or glass surfaces. 6. The bivalve battery according to claim 2, wherein the sealing material disposed between the projections of the upper half of the bivalve configuration and the lower half of the bivalve configuration comprises a plurality of thin layers of metal films, the first thin layer of metal film applied to the second layer of metal film the metal film layer is made with the possibility of chemical reaction with the second metal film layer with the release of energy for the rapid heating of the layers, and moreover The energy is activated by the energy impulse. 7. The bicuspid battery according to claim 6, wherein the energy pulse contains photons. 8. The bicuspid battery according to claim 6, in which the energy pulse contains electrons. 9. The bicuspid battery according to claim 6, in which the energy pulse contains thermal energy. 10. The bicuspid battery according to claim 2, further comprising a metal coating covering at least part of the outer surface of the bivalve battery, the metal coating being applied by chemical reduction. 11. Bivalve battery according to claim 2, in which the sealing material placed in the gap between the first sealing surface and the first metal flap of the bivalve configuration contains a standard soft solder with the addition of titanium, and the titanium reacts with the materials of the ceramic surface when exposed to ultrasonic energy. 12. A two-leaved battery containing: the anode current lead, the anode current lead being the first metal flap of a bivalve configuration; the anode, and the chemical structure of the anode is contained within the first metal sash of a bicuspid configuration; the cathode current lead, and the cathode current lead is a second metal sash bivalve configuration; a cathode, the chemical structure of the cathode being contained within the second metal flap of a bivalve configuration; insulating the intermediate flap of the bicuspid configuration with the first sealing surface, which is adapted to interact in a sealing manner with the first metal flap of the double configuration, and the second sealing surface, which is configured to interact in a sealing manner with the second metal flap of the double configuration; and sealing material, which is placed in the gap between the first sealing surface and the first metal sash of the bivalve configuration. 13. The bicuspid battery according to claim 12, wherein the sealing material disposed in the gap between the first sealing surface and the first metal flap of the bivalve configuration is an epoxy adhesive. 14. The bicuspid battery according to claim 12, wherein the sealing material disposed between the protrusions of the first metal sash of the bicuspid configuration and the insulating intermediate sash of the bicuspid configuration comprises a plurality of thin metal film layers, the first thin metal film layer being applied to the second metal film layer, and the first thin layer of metal film is made with the possibility of chemical reaction with the second layer of metal film with the release of energy for rapid heating and layers, and moreover, the chemical reaction is activated energy pulse of energy. 15. The bicuspid battery according to claim 14, wherein the energy pulse contains photons. 16. The bicuspid battery according to claim 14, wherein the energy pulse contains electrons. 17. The bicuspid battery according to claim 14, wherein the energy pulse comprises thermal energy. 18. The bicuspid battery according to claim 12, further comprising a metal coating covering at least a portion of the outer surface of the bivalve battery, wherein the metal coating is applied by chemical reduction, with at least a fully coated portion of the intermediate flap of a bivalve configuration protected from metal coating and provides insulation between the first metal casement of the bicuspid configuration and the second metal casement of the bicuspid configuration. 19. The bivalve battery according to claim 12, in which the sealing material housed in the gap between the first sealing surface and the first metal flap of the bivalve configuration contains standard soft solder with the addition of titanium, and the titanium can react with the materials of the surface of the intermediate leaf of the bivalve configuration exposure to ultrasound energy. 20. A double battery containing: the anode current lead, with the anode current lead being the first plastic flap of a bivalve configuration; the anode, and the chemical structure of the anode is contained within the first plastic flap of the double-leaf configuration; the cathode current lead, and the cathode current lead is a second plastic flap of bivalve configuration; the cathode, with the chemical structure of the cathode contained within the second plastic flap of the bivalve configuration; and a seal comprising a molten region comprising protrusions of a first plastic flap of a double-leaf configuration and a second plastic flap of a double-leaf configuration. 21. The bicuspid battery according to claim 20, wherein the shape of the first plastic flap of the bivalve configuration and the second plastic flap of the bivalve configuration comprises an uneven transverse profile that is shaped to fill the volume inside the ophthalmic lens. 22. The bicuspid battery according to claim 20, wherein the sealing material disposed between the projections of the first plastic cusp of the bicuspid configuration and the second plastic cusp of the bivalve configuration contains a plurality of thin layers of metal films, the first thin layer of metal film applied to the second layer of metal film the first thin layer of metal film is made with the possibility of chemical reaction with the second layer of metal film with the release of energy for rapid heating of the layer And wherein the chemical reaction is activated by the energy pulse energy. 23. The bicuspid battery according to claim 22, in which the energy pulse contains photons. 24. The bicuspid battery according to claim 22, in which the energy pulse contains electrons. 25. The bicuspid battery according to claim 22, in which the energy pulse contains thermal energy. 26. The bicuspid battery according to claim 20, wherein the metal film covers portions of the inner surfaces of the first plastic flap of the bivalve configuration and the second plastic flap of the double leaf configuration, and the metal film coating on the first plastic flap of the double configuration is electrically isolated from the metal film coating on the second plastic double flap configuration when the double battery is not connected to an electrical device. 27. The bivalve battery according to claim 20, further comprising a metal coating covering at least part of the outer surface of the bivalve battery, the metal coating being applied by chemical reduction, at least one of the following contacts from the first anode contact first cathode contact - protected from metal coating and electrically isolated from the metal coating. 28. A two-leaved battery containing: an anode current lead, the anode current lead being the first semiconductor leaf of a bivalve configuration; the anode, and the chemical structure of the anode is contained within the first semiconductor flap of a bivalve configuration; the cathode current lead, the cathode current lead being the second semiconductor leaf of the bivalve configuration; a cathode, with the chemical structure of the cathode contained within the second semiconductor flap of a bivalve configuration; a seal between the projections of the first semiconductor flap of the bivalve configuration and the second semiconductor leaf of the bivalve configuration; and moreover, the isolated regions of the first semiconductor flap of the bivalve configuration and the second semiconductor flap of the bivalve configuration are doped for current flow through the doped regions from the battery to the external connection. 29. The bicuspid battery according to claim 28, wherein the shape of the first semiconductor leaf of the bivalve configuration and the second semiconductor leaf of the bivalve configuration comprises an uneven transverse profile that is shaped to fill the volume inside the ophthalmic lens. 30. The bicuspid battery according to claim 28, wherein the sealing material disposed between the protrusions of the first plastic leaf of the bicuspid configuration and the second semiconductor leaf of the bivalve configuration contains a plurality of thin layers of metal films, the first thin layer of metal film applied to the second layer of metal film the first thin layer of metal film is made with the possibility of chemical reaction with the second layer of metal film with the release of energy for rapid heating with Oev, and wherein the chemical reaction is activated by the energy pulse energy. 31. The bicuspid battery according to claim 30, wherein the energy pulse contains photons. 32. The bicuspid battery according to claim 30, in which the energy pulse contains electrons. 33. The bicuspid battery according to claim 30, in which the energy pulse contains thermal energy. 34. The bicuspid battery according to claim 28, wherein the metal film covers portions of the inner surfaces of the first semiconductor flap of the bivalve configuration and the second semiconductor flap of the bivalve configuration, wherein the coating of the metal film on the first flap of the double-leaf configuration is electrically connected to the coating of the metal film on the second flap of the double configuration through anode, separator and cathode only when the double-walled battery is not connected to an electrical device. 35. The bicuspid battery according to claim 28, further comprising a metal coating covering at least part of the outer surface of the bivalve battery, the metal coating being applied by chemical reduction, and at least one of the following contacts is from the first anode contact and first cathode contact - protected from metal coating and electrically isolated from the metal coating. 36. A method of manufacturing a bivalve battery, comprising the steps of: get the first half of the bivalve configuration and the second half of the bivalve configuration, made of insulating material, with half of the bivalve configuration contain a housing section to support the battery component around which the protrusion is located, and the protrusion is configured to be used for sealing; form a conductive path in the first half of the double configuration; placing the anode in the first half of the bicuspid configuration; placing the cathode in the second half of the bicuspid configuration; placing a release film on one or both of the first half of the bivalve configuration and the second half of the bivalve configuration; place the electrolyte in one or both of the halves of the bivalve configuration - the first half of the bivalve configuration and the second half of the bivalve configuration; connect halves of bivalve configuration; and form a seal between the protrusions of the halves of the double configuration. 37. The method of claim 36, further comprising sealing at least the surface areas of the first half of the bivalve configuration and the second half of the bivalve configuration by coating by chemical reduction. 38. The method according to p. 37, further comprising a metal coating of a bivalve battery by electrolytic deposition. 39. The method of claim 36, further comprising coating at least the first portion of one or both of the halves of the bivalve configuration — the first half of the bivalve configuration and the second half of the bivalve configuration — by depositing a metal film by vapor deposition. 40. The method according to claim 36, further comprising coating at least the first portion of the projections of one or both of the halves of the bivalve configuration — the first half of the bivalve configuration and the second half of the bivalve configuration — with a metal film for sealing. 41. The method according to p. 36, further comprising placing a bivalve battery in an ophthalmic device. 42. The method of claim 41, wherein the ophthalmic device is a contact lens. 43. A method of manufacturing a bivalve battery, comprising the steps of: get the first half of the bivalve configuration and the second half of the bivalve configuration, made of plastic material, with half of the bivalve configuration contain a housing section to support the battery component around which the protrusion is located, and the protrusion can be used for sealing; form a conductive path in the first half of the double configuration; placing the anode in the first half of the bicuspid configuration; placing the cathode in the second half of the bicuspid configuration; placing a release film on one or both of the halves of the bivalve configuration — the first half of the bivalve configuration and the second half of the bivalve configuration; place the electrolyte in one or both of the halves of the bivalve configuration - the first half of the bivalve configuration and the second half of the bivalve configuration; connect halves of bivalve configuration; form a seal between the protrusions of the halves of the bicuspid configuration, and the formation of a seal includes fusing the plastic protrusions of the first half of the bicuspid configuration and the second half of the bicuspid configuration; and seal at least the surface areas of the first half of the bivalve configuration and the second half of the bivalve configuration by coating by chemical reduction. 44. The method according to claim 43, further comprising a metal coating of a bivalve battery by electrolytic deposition. 45. The method of claim 43, further comprising coating at least the first portion of one or both of the halves of the bivalve configuration — the first half of the bivalve configuration and the second half of the bivalve configuration — by depositing a metal film by deposition from the gas phase. 46. A method of manufacturing a bivalve battery, comprising the steps of: get the first half of the bivalve configuration, made of semiconductor material, and the second half of the bivalve configuration, made of semiconductor material, and half of the bivalve configuration contain a portion of the housing to support the battery component, around which the protrusion, and the protrusion made with the possibility of sealing; the sites are doped on one or both of the halves of the bivalve configuration - the first half of the bivalve configuration and the second half of the bivalve configuration, and doping increases the conductivity of the material to form the contact area; put a metal film on the surface of the first half of the double configuration; placing the anode in the first half of the bicuspid configuration; placing the cathode in the second half of the bicuspid configuration; placing a release film on one or both of the halves of the bivalve configuration — the first half of the bivalve configuration and the second half of the bivalve configuration; place the electrolyte in one or both of the halves of the bivalve configuration - the first half of the bivalve configuration and the second half of the bivalve configuration; connect halves of bivalve configuration; form a seal between the projections of the halves of the double configuration; and seal at least the surface areas of the first half of the bivalve configuration and the second half of the bivalve configuration by coating by chemical reduction. 47. The method of claim 46, further comprising coating the bivalve battery by electrolytic deposition. 48. The method according to claim 46, further comprising covering at least the first portion of one or both of the halves of the bivalve configuration — the first half of the bivalve configuration and the second half of the bivalve configuration — by applying an insulating film by vapor deposition. 49. The method of claim 46, further comprising placing the bivalve battery in the ophthalmic device. 50. The method of claim 49, wherein the ophthalmic device is a contact lens.