Flexible thin layer open electrochemical cell

Abstract

A flexible thin layer open liquid state electrochemical cell which can be used as a primary or rechargeable power supply for various miniaturized and portable electrically powered devices of compact design. The cell includes a wet electrolyte, yet maintains a fexible, thin and open configuration, thus devoid of accumulation of gases upon storage. The cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, the third layer being disposed between the first and second layers and including a deliquescent material for keeping the open cell wet at all times; an electroactive soluble material for obtaining required ionic conductivity; and, a watersoluble polymer for obtaining a required viscosity for adhering the first and second layers to the third layer. The electrochemical cell of the present invention is preferably produced using a suitable printing technology.

1. A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layer and including:
 (a) a deliquescent material for keeping the open cell wet at all times;    (b) an electroactive soluble material for obtaining required ionic conductivity; and    (c) a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer.    
     
     
       2. A cell as in  claim 1 , wherein said first layer of insoluble positive pole includes manganese-dioxide powder and said second layer of insoluble negative pole includes zinc powder. 
     
     
       3. A cell as in  claim 2 , wherein  A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer; wherein said first layer of insoluble negative pole includes zinc powder, said second layer of insoluble positive pole includes manganese - dioxide powder, and  said electroactive soluble material is selected from the group consisting of zinc-chloride, zinc-bromide, zinc-fluoride and potassium-hydroxide.  
 
     
     
       4. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said first layer of insoluble negative pole includes silver-oxide powder  zinc powder and said second layer of insoluble positive pole includes zinc powder  silver- oxide powder.    
 
     
     
       5. A cell as in  claim 4 , wherein said electroactive soluble material is potassium-hydroxide. 
     
     
       6. A cell as in  claim 1   A flexible thin layer open liquid state electrochemial cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said first layer of insoluble negative pole includes cadmium powder and said second layer of insoluble positive pole includes nickel-oxide powder.  
 
     
     
       7. A cell as in  claim 6 , wherein said electroactive soluble material is potassium-hydroxide. 
     
     
       8. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said first layer of insoluble negative pole includes iron powder and said second layer of insoluble positive pole includes nickel-oxide powder.  
 
     
     
       9. A cell as in  claim 8 , wherein said electroactive soluble material is potassium-hydroxide. 
     
     
       10. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said first layer of insoluble negative pole and said second layer of insoluble positive pole include lead-oxide powder, the cell is charged by voltage applied to said poles.  
 
     
     
       11. A cell as in  claim 10 , wherein said electroactive soluble material is sulfuric-acid. 
     
     
       12. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said deliquescent material and said electroactive soluble material are the same material.  
 
     
     
       13. A cell as in  claim 12 , wherein said same material is selected from the group consisting of zinc-chloride, zinc-bromide, zinc-fluoride and potassium-hydroxide. 
     
     
       14. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said deliquescent material is selected from the group consisting of calcium-chloride, calcium-bromide, potassium-biphosphate and potassium-acetate.  
 
     
     
       15. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said watersoluble polymer is selected from the group consisting of polyvinylalcohol, polyacrylamide, polyacrylic acid, polyvinylpyrolidone, polyethylenoxide, agar, agarose, starch, hydroxyethylcellulose and combinations and copolymers thereof.  
 
     
     
       16. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , wherein said watersoluble polymer and said deliquescent material are the same material.  
 
     
     
       17. A cell as in claim  1    16 , wherein said same material is selected from the group consisting of dextrane, dextranesulfate and combinations and copolymers thereof. 
     
     
       18. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , further comprising terminals, each of said terminals being in electrical contact with one of said first and second pole layers.  
 
     
     
       19. A cell as in  claim 18 , wherein said terminal  terminals are made of graphite. 
     
     
       20. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , further comprising at least one conductive layer improving the electronic conductivity of at least one of said first and second pole layers.  
 
     
     
       21. A cell as in  claim 20 , wherein said conductive layer is selected from the group consisting of a graphite paper and carbon cloth. 
     
     
       22. A cell as in  claim 1   A flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer , further comprising an external layer selected from the group consisting of an adhesive backing layer, a lamina protective layer and a combination of adhesive backing layer and a lamina protective layer.  
 
     
     
       23. An electrical power supply comprising two cells as in  claim 1   being connected in a head to tail orientation in a bipolar-connection wherein the cells are each a flexible thin layer open liquid state electrochemical cell comprising a first layer of insoluble negative pole, a second layer of insoluble positive pole and a third layer of aqueous electrolyte, said third layer being disposed between said first and second layers and including:
 ( a )  a deliquescent material for keeping the open cell wet at all times;    
 ( b )  an electroactive soluble material for obtaining required ionic conductivity; and    
 ( c )  a watersoluble polymer for obtaining a required viscosity for adhering said first and second layers to said third layer.    
 
     
     
       24. An electrical power supply as in  claim 23 , wherein said connection is by an adhesive selected from the group consisting of a conductive double sided adhesive tape and a conductive glue layer. 
     
     
       25. An electrical power supply as in  claim 24 , wherein said conductive double sided adhesive tape and said conductive glue layer are applied by a printing technology. 
     
     
       26. A method of making a flexible thin layer open liquid state electrochemical cell comprising the steps of:
 (a) wetting a porous substance having a first side and a second side with an aqueous solution containing a deliquescent material, an electroactive soluble material and a watersoluble polymer;  
 (b) applying onto said first side a layer of negative pole; and  
 (c) applying onto said second side a layer of positive pole.  
 
     
     
       27. A method as in  claim 26 , wherein said wetting is by a dipping technology. 
     
     
       28. A method as in  claim 26 , wherein said wetting is by a printing technology. 
     
     
       29. A method as in  claim 26 , wherein said layers of negative and positive poles include active insoluble powder materials mixed with said deliquescent material, electroactive soluble material and watersoluble polymer. 
     
     
       30. A method as in  claim 26 , wherein said application of said layers of negative and positive poles is by a printing technology.