Battery tab and packaging frame design

Abstract

Improved battery packaging and constructions for batteries, particularly thin, flat-profile packaged batteries are provided. The battery packaging constructions may eliminate the need for soldering by providing current collector tabs coated by electrically conductive adhesive tape such as z-axis conductive tape and may provide support for current collector tabs and a regular battery perimeter by providing supportive battery packaging and/or frame materials. Better fabrication results, particularly when the batteries are used in smart cards, RFID tags, and medical devices.

1 - 8 . (canceled) 
     
     
         9 . A battery comprising:
 (a) a battery cell;   (b) at least one current collector tab having a distal end extending from the battery cell; and   (c) a lower packaging material disposed below the battery cell and having an outer edge that extends beyond a periphery of the battery cell; wherein the lower packaging material supports the at least one current collector tab.   
     
     
         10 . The battery of  claim 9 , wherein the outer edge of the lower packaging material is substantially flush with the distal end of the at least one current collector tab. 
     
     
         11 . The battery of  claim 9 , wherein the outer edge of the lower packaging material is not substantially flush with the distal end of the at least one current collector, and the distal end of the current collector extends beyond the outer edge of the lower packaging material. 
     
     
         12 . The battery of  claim 9  further comprising an upper packaging material disposed above the battery cell wherein the upper and lower packaging materials provide a pouch for the battery cell. 
     
     
         13 . The battery of  claim 12  wherein the upper packaging material and the lower packaging material are comprised of a single continuous piece of packaging material. 
     
     
         14 . The battery of  claim 12  wherein the upper packaging material has an outer edge that does not extend to the distal end of the at least one current collector tab. 
     
     
         15 . The battery of  claim 9 , further comprising an electrically conductive tape disposed over the at least one current collector tab. 
     
     
         16 . The battery of  claim 15 , wherein the electrically conductive tape has an outer edge that is substantially flush with the distal end of the at least one current collector tab and an inner edge that is directed toward the outer edge of the upper packaging material. 
     
     
         17 . The battery of  claim 16 , wherein a gap is defined between the inner edge of the electrically conductive tape and the outer edge of the upper packaging material. 
     
     
         18 . The battery of  claim 15 , wherein the electrically conductive tape comprises a z-axis anisotropic electrically conductive tape. 
     
     
         19 . The battery of  claim 12 , having a raised middle portion, the battery further comprising an external frame seated around the raised middle portion. 
     
     
         20 . The battery of  claim 19 , wherein external frame has a height that is substantially equal to height of the raised middle portion. 
     
     
         21 . The battery of  claim 9 , wherein the battery is a lithium metal battery, a lithium ion battery or a polymer electrolyte battery. 
     
     
         22 . The battery of  claim 9 , wherein the battery comprises an electrolyte comprising polyimide, lithium salt, and solvent. 
     
     
         23 . An electronic device comprising the battery of  claim 9  and an electronic circuit. 
     
     
         24 . The device of  claim 23  wherein an electrical connection between the at least one current collector tab and the electronic circuit is established without a weld or solder. 
     
     
         25 . The device of  claim 23 , wherein the device is a smart card, a smart label, an electronically readable card, an RFID tag, an electrically powered label, a medical device, a sensor, a temperature measurement device, or a wearable medical device. 
     
     
         26 - 43 . (canceled)