United States Patent
`
`USOOS432027A
`5,432,027
`[11] Patent Number:
`
`[45] Date of Patent:
`Jul. 11, 1995
`Tuttle et al.
`
`[19]
`
`[54] BUTTON-TYPE BATTERY HAVING
`BENDABLE CONSTRUCTION, AND
`ANGLED BUTTON-TYPE BATTERY
`
`[75]
`
`[73]
`
`Inventors: Mark E. Tuttle; Peter M. Blonsky,
`both of Boise, Id.
`
`Assignee: Micron Communications, Inc., Boise,
`Id.
`
`[21]
`
`App]. No.: 205,957
`
`[22]
`
`[51]
`[521
`[58]
`
`[56]
`
`Filed:
`Mar. 2, 1994
`Int. 01.6 .................. H01M 2/02
`
`
`US. Cl. ........................... 429/127; 429/ 174
`Field of Search ................ 429/ 127, 174, 175, 176
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`2,422,045 6/ 1 947 Ruben ................................. 136/167
`
`..... 136/107
`2,712,565
`7/1955 Williams, Jr.
`
`9/1960 Kempf .................. 136/169
`2,951,891
`3,023,259
`2/1962 Color et a1.
`.
`..... 429/ 127
`
`
`7/1963 Clune ................... 136/ 107
`3,096,217
`3,185,595
`5/1965 Schenk, Jr.
`..... 136/133
`
`3,440,110 4/1969 Arbter .................. 136/166
`3,457,117
`7/1969 Angelovich .
`..... 136/ 133
`3,663,000
`6/1972 Ruetschi ..
`..... 136/ 107
`3,708,343
`1/1973 Walsh ............... 136/133
`3,713,896
`1/1973 Feldhake .......... 136/133
`
`3,799,959 3/ 1974 Epstein ............. 260/429
`6/1975 Langkau .............................. 136/111
`3,891,462
`
`
`
`3,935,026
`1/ 1976 Howard ................................ 136/20
`4,048,405
`9/1977 Megahed .....
`429/206
`
`4,121,020 10/1978 Epstein et a1.
`..........
`429/174
`429/133
`4,122,241 10/1978 Ciliberti, Jr. et a1.
`
`429/162
`.......................
`4,263,380
`4/1981 Riedl
`
`429/174
`4,374,909 2/ 1983 Tucholski ........
`
`429/174
`4,501,805
`2/1985 Yasuda et a1.
`.. 429/181
`
`..
`4,632,887 12/1986 Jung .............
`7/1994 Lake .................................... 429/ 127
`5,326,652
`
`FOREIGN PATENT DOCUMENTS
`
`1099018 11/1959 Germany .................................. 10/1
`2201811
`1/1972 Germany ................................ 21/84
`
`Primary Examiner—Stephen Kalafut
`Attorney, Agent, or Firm—Wells, St. John, Roberts,
`Gregory & Matkin
`
`[5 7]
`
`ABSTRACT
`
`A button—type battery has an anode, a cathode, a separa-
`tor, and an electrolyte encased within a housing and
`surrounding by a fluid-tight peripheral seal. The battery
`is capable of being deflected such that a first portion of
`the battery is angled relative to a second portion
`through an internal angle between the first and second
`portions in a range from 175° to at least 90° without
`destroying operation of the button-type battery or rup-
`turing the fluid»tight peripheral seal.
`
`21 Claims, 5 Drawing Sheets
`
`
`
`JLab/Cambridge, Exh. 1019, p. 1
`
`JLab/Cambridge, Exh. 1019, p. 1
`
`

`

`US. Patent
`
`July 11, 1995
`
`Sheet 1 of 5
`
`5,432,027
`
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`FRIMR ”ELK/Cambridge, EXh. 1019, p. 2
`
`JLab/Cambridge, Exh. 1019, p. 2
`
`

`

`US. Patent
`
`July 11, 1995
`
`Sheet 2 of 5
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`95
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`432,027
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`

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`US. Patent
`
`July 11, 1995
`
`Sheet 3 of 5
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`5,432,027
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`JLab/C’ambridge, Exh. 1019, p. 4
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`JLab/Cambridge, Exh. 1019, p. 4
`
`

`

`US. Patent
`
`July 11, 1995
`
`Sheet 4 of 5
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`JLab/Cambridge, Exh. 1019, p. 5
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`JLab/Cambridge, Exh. 1019, p. 5
`
`

`

`US. Patent
`
`‘July 11, 1995
`
`Sheet 5 of 5
`
`5,432,027
`
`
`
`JLab/Cambridge, Exh. 1019, p. 6
`
`JLab/Cambridge, Exh. 1019, p. 6
`
`

`

`1
`
`5,432,027
`
`_ BUTTON-TYPE BATTERY HAVING BENDABLE
`CONSTRUCTION, AND ANGLED BUTTON-TYPE
`BATTERY
`
`TECHNICAL FIELD
`
`This invention relates to button-type batteries.
`
`BACKGROUND OF THE INVENTION
`
`Button-type batteries are small thin energy cells that
`are commonly used in watches and other electronic
`devices requiring a thin profile. FIGS. 1 and 2 show a
`conventional button-type battery 20. Battery 20 in-
`cludes an anode 22, a cathode 24, a porous separator 26
`separating the anode and cathode, and an electrolyte 28
`which facilitates ion conductivity between the anode
`and cathode.
`
`These internal battery components are housed within
`a metal casing formed by a lower conductive can 30 and
`an upper conductive lid 32. Can 30 electrically contacts
`cathode 24 and thereby forms the positive battery ter-
`minal. Lid 32 electrically contacts anode 22 to form the
`negative battery terminal. The can and lid are crimped
`or pressed together to form a fluid-tight seal 34 which
`entirely encloses the anode, cathode, separator, and
`electrolyte. An insulating gasket 36 is provided within
`primary seal 34 between lid 32 and can 30 to electrically
`insulate the two housing members.
`There is a need in button-type battery usage to make
`such energy cells thinner. Today, the thinnest commer-
`cially available button-type battery has a thickness of
`1.2 mm (47.2 mils). It would be desirable to make a
`thinner battery, particularly one having a thickness of
`less than 1 mm (39.4 mils). A countering concern, how-
`ever, is that the integrity of the fluid-tight seal cannot be
`compromised simply to achieve the goal of thinner
`batteries.
`
`Accordingly, it is desirable to design a button-type
`battery with a very thin profile, yet without degrading
`the integrity of the fluid-tight seal.
`There is an evolving market for button-type batteries
`in personal carrying cards which employ such batteries.
`For example, smart cards, battery-back RAMs (Ran-
`dom Access Memories), and some credit cards are being
`manufactured with integrated circuitry and memory
`components that require a power source. It is desirable
`to form such integrated circuit cards as thin as standard
`magnetic—stripe credit cards which are widely used
`today. Credit cards have a nominal thickness require-
`ment of approximately 30 mils (0.762 mm). A thin but—
`ton-type battery of less than 30 mils (0.762 mm) thick-
`ness would be ideal for use in such integrated circuit
`carrying cards. However, conventional button-type
`batteries are too thick, inflexible and their seals easily
`rupture when bent. Once the fluid-tight seal ruptures,
`the electrolyte leaks from the battery, rendering the
`battery inoperable.
`It would therefore be desirable to design a thin but-
`ton-type battery with a thickness of less than 30 mils
`(0.762 mm), yet having high integrity seals that could be
`flexed and bent without destroying operation of the
`battery or rupturing the seal.
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Preferred embodiments of the invention are de-
`scribed below with reference to the following accompa-
`nying drawings. The same components and features
`
`2
`illustrated throughout the drawings are referenced with
`like numerals.
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`4O
`
`45
`
`50
`
`55
`
`60
`
`65
`
`FIG. 1 is a top view of a prior art button-type battery.
`FIG. 2 is a cross-sectional view taken along line 2—2
`in FIG. 1 of the prior art button-type battery.
`FIG. 3 is a top view of a button-type battery accord-
`ing to this invention.
`FIG. 4 is a cross-sectional View taken along line 4—4
`in FIG. 3 of the button-type battery.
`FIG. 5 is an enlarged cross—sectional View taken
`within circle 5 of FIG. 4 and shows a C-shaped fluid-
`tight crimp seal according to this invention.
`FIG. 6 is an enlarged cross-sectional view similar to
`that taken in circle 5 of FIG. 4 and shows a modified
`C-shaped fluid-tight crimp seal according to another
`aspect of this invention.
`FIG. 7 is a side view of the FIG. 3 button-type bat-
`tery where a portion of the battery is angled relative to
`another portion of the battery.
`FIG. 8 is a cross-sectional view similar to that taken
`along line 4—4 in FIG. 3, but showing the angled bat-
`tery of FIG. 6.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`
`This disclosure of the invention is submitted in fur-
`
`therance of the constitutional purposes of the US. Pa-
`tent Laws “to promote the progress of science and
`useful arts” (Article 1, Section 8).
`This invention concerns “coin” or “button-type”
`batteries. A button-type battery is typically a small
`circular-shaped energy cell approximately the size of a
`coin. The button-type battery can be constructed in
`different sizes, with typical diameters being 12 mm, 16
`mm, and 20 mm. Other shapes are possible, but the
`circular shape is most common.
`According to one aspect of this invention, a button—
`type battery comprises:
`an integral button-type energy cell unit having an
`anode, a cathode, a separator, and an electrolyte
`encased within a housing, the housing having a
`fluid-tight peripheral seal; and
`the integral button-type energy cell unit having first
`and second portions intermediate of the peripheral
`seal, the first portion being deflectable relative to
`the second portion through an internal angle be-
`tween the first and second portions in a range from
`175° to at least 90° without destroying operation of
`the button-type battery or rupturing the fluid-tight
`peripheral seal.
`According to another aspect of this invention, a but—
`ton-type battery comprises:
`an anode aligned along a transverse central axis;
`a cathode positioned adjacent
`to the anode and
`aligned along the transverse central axis;
`a separator between and separating the anode and the
`cathode;
`an electrolyte between the anode and the cathode;
`a conductive first terminal housing member in electri—
`cal contact with one of the anode or the cathode;
`the first terminal housing member having a periph-
`cry;
`a conductive second terminal housing member in
`electrical contact with the other of the anode or the
`cathode; the second terminal housing member hav-
`ing a periphery projecting substantially radially
`outward from the central axis;
`
`JLab/Cambridge, Exh. 1019, p. 7
`
`JLab/Cambridge, Exh. 1019, p. 7
`
`

`

`5,432,027
`
`3
`the first and second terminal housing members form-
`ing an enclosed housing which holds and protects
`the anode and the cathode;
`an insulating gasket between the first and second
`terminal housing member peripheries to electri-
`cally insulate the first terminal housing member
`from the second terminal housing member;
`the first terminal housing member periphery and the
`insulating gasket wrapping around three sides of
`the second terminal housing member periphery to
`form a fluid-tight peripheral crimp seal which flu-
`idically seals the anode and the cathode within the
`housing formed by the first and second terminal
`housing members, the first terminal housing mem-
`ber periphery having two segments on opposing
`sides of the second terminal housing member pe-
`riphery and a continuously bending segment on a
`third side of the second terminal housing member
`periphery connecting the two segments; and
`the anode, the cathode, the separator, and the first
`and second terminal housing members having an
`effective total combined thickness and the periph-
`eral crimp seal having an effective seal integrity to
`permit flexibility of the button—type battery where
`one portion of the button-type battery intermediate
`of the peripheral crimp seal can be deflected rela-
`tive to another portion of the button-type battery
`intermediate of the peripheral crimp seal through
`an internal angle between the two portions in a
`range of 175° to at least 90" without destroying
`operation of the button—type battery or rupturing
`the fluid-tight peripheral crimp seal.
`Research culminating in the invention disclosed
`herein also resulted in other inventions. These other
`inventions are the subject of other U.S. patents which
`spawned from patent applications filed on the same day
`of the patent application from which this U.S. patent
`matured. These other patent applications are US. pa-
`tent application Ser. No. 08/206,051, “Method Of Pro—
`ducing Button-Type Batteries And Spring-Biased Con-
`cave Button-Type Battery”, listing John R. Tuttle and
`Mark E. Tuttle as inventors US. patent application Ser.
`No. 08/205,590, “Methods Of Producing Button-Type
`Batteries And A Plurality Of Battery Terminal Housing
`Members”, listing Rickie Lake and Peter M. Blonsky as
`inventors
`and US. patent
`application Ser. No.
`08/205,611, “Button-Type Battery With Improved Sep-
`arator And Gasket Construction”,
`listing Peter M.
`Blonsky and Mark E. Tuttle as inventors These co-filed
`patent applications and resulting patents are hereby
`incorporated by reference as if fully included herein.
`FIGS. 3—5 show a button-type battery 40 according
`to a first preferred embodiment of this invention. Bat~
`tery 40 has an anode 42, a cathode 44 positioned adja-
`cent to the anode, and a liquid electrolyte 46 between
`the anode and cathode. Anode 42 and cathode 44 are
`aligned along a transverse central axis 45.
`Button-type battery 40 also includes a circular con-
`ductive first, lower, or bottom terminal housing mem-
`ber 48 which forms the can of the energy cell. First
`terminal housing member 48 has a central portion 50 in
`electrical contact with cathode 44 and a periphery 52
`surrounding central portion 50. First housing member
`48 defines the positive battery terminal because it
`contacts cathode 44.
`
`Battery 40 has a circular conductive second, upper,
`or top terminal housing member 54 which forms the lid
`of the energy cell. The second terminal housing mem-
`
`4
`ber 54 has a central portion 56in electrical contact with
`anode 42 and a periphery 58 surrounding central por-
`tion 56. By contacting anode 42, second housing mem-
`ber 52 defines the negative battery terminal. First and
`second terminal housing members 48 and 54 combine to
`form an enclosed housing 60 which holds and protects
`anode 42, cathode 44, and electrolyte 46. It should be
`noted that the first and second terminal housing mem-
`bers 48 and 54 can be alternately reversed to electrically
`contact anode 42 and cathode 44, respectively, thereby
`reversing their respective terminal polarities.
`Anode 42, cathode 44, and electrolyte 46 can be
`formed of conventional construction. For example, in
`the reduction to practice models, anode 42 comprises
`elemental lithium provided on a copper backed foil.
`Anode 42 has a preferred thickness of approximately 2
`mils (0.0508 mm). Cathode 44 is formed of a compressed
`tablet made from a composite of manganese (IV) oxide,
`carbon, and teflon powder. Cathode 44 has a preferred
`thickness of 8 mils (0.2032 mm).
`An example electrolyte 46 comprises a solution of
`propylene
`carbonate
`and ethylene glycol dime-
`thylether, having dissolved lithium tetrafluoroborate.
`Suitable electrolyte components are supplied by Ald-
`rich Chemical Company of Milwaukee, Wis. The vol-
`ume of electrolyte 46 provided within first terminal
`housing member 48 is preferably gauged to fill the sub—
`stantial void within housing member 48, yet not so great
`to leak upon crimp sealing the battery assembly.
`First and second terminal housing members 48 and 52
`are preferably formed of a conductive material having a
`thickness of less than 8 mils (0.2032 mm), with a thick-
`ness in a range of approximately 3—5 mils (0.0762—0. 1270
`mm) being more preferred, and a thickness of 4 mils
`(0.1016 mm) being most preferred. An example material
`used for the terminal housing members is Type 304
`stainless steel manufactured by Teledyne Rodney Met-
`als of New Bedford, Mass.
`An insulating gasket 62 is provided between first and
`second terminal housing member peripheries 52 and 58
`to electrically insulate first terminal housing member 48
`from second terminal housing member 54. Gasket 62 is
`preferably formed of an epoxy resin that
`is screen
`printed onto can periphery 52 of first terminal housing
`member 48. Gasket 62 can alternately be deposited onto
`all three sides 58a, 58b, 58c of lid periphery 58 of second
`terminal housing member 54. The gasket can be formed
`of one or more layers of epoxy resins, with varying
`degrees of hardness. An example composite gasket has a
`harder outer epoxy layer adjacent to battery can periph-
`ery 52 and an inner softer epoxy layer. Epoxy gasket
`material of different resultant hardness are available
`from Electronics Materials, Inc., of Brookfield, Conn.
`Altemately, gasket 62 can be formed of other insulative
`materials, such as polyimide.
`First and second terminal housing member peripher-
`ies 52 and 58 and insulating gasket 62 are configured
`together to form a fluid-tight peripheral seal 64 which
`fluidically seals anode 42, cathode 44, and electrolyte 46
`within housing 60. Peripheral seal 64 is preferably a
`C—shaped crimp seal. This crimp seal is constructed by
`bending can periphery 52 about lid periphery 58.
`FIG. 5 shows the C-shape peripheral crimp seal 64 is
`more detail. Second terminal housing member periph-
`ery 58 is substantially planar within the seal and projects
`substantially radially outward from central axis 45 (i.e.,
`horizontal
`in the drawings). First
`terminal housing
`member periphery 52 and insulating gasket 62 wrap
`
`5
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`15
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`25
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`30
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`35
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`40
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`45
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`50
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`60
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`65
`
`JLab/Cambridge, Exh. 1019, p. 8
`
`JLab/Cambridge, Exh. 1019, p. 8
`
`

`

`5,432,027
`
`5
`around three sides 58a, 58b, 58c of battery lid periphery
`58. First terminal housing member periphery 52 consists
`of two substantially planar segments 66 and 68 on re-
`spective opposing sides 58a and 586 of the substantially
`planar second terminal housing member 58 and a con-
`tinuously bending segment 70 on side 58b of lid periph—
`ery 58. Continuously bending segment 70 connects
`upper segment 66 and lower segment 68 and has an
`example radius of curvature of 3.5 mils (0.0889 mm).
`Most preferably, the planar lid periphery 58 and the
`planar upper and lower segments 66 and 68 of can pe-
`riphery 52 are all substantially in parallel.
`The action associated with forming C-shape periph-
`eral crimp seal 64 produces an indentation in circular
`first terminal housing member 48. This is caused by the
`thickness of housing member 48 and the radius of bend-
`ing segment 70 being in combination effectively small to
`induce compressive stresses which result in such up-
`ward contractiOn.
`Button-type battery 40 also includes a separator 72
`provided between anode 42 and cathode 44. Separator
`72 includes a central portion 74 which physically sepa-
`rates anode 42 and cathode 44 and a peripheral portion
`76 surrounding central portion 74. Separator peripheral
`portion 76 extends between the first and second termi-
`nal housing member peripheries 52 and 58 at least par—
`tially into peripheral seal 64. More particularly, separa-
`tor periphery 76 is interposed between insulating gasket
`62 and lid periphery 58 to thereby partially overlap with
`insulating gasket 62. It should be noted that when gas-
`ket 62 is deposited onto lid periphery 58, separator
`periphery 76 will be interposed between insulating gas-
`ket 62 and can periphery 52.
`Separator 72 is preferably formed of a woven or
`porous polymeric material, such as polyethylene, poly-
`propylene, or teflon. Separator 72 has unidirectional
`pores formed in the Z direction parallel to central axis
`45 to facilitate electrolytic conductivity between anode
`42 and cathode 44. Separator 72 has a preferable thick-
`ness of 1 mil (0.0254 mm). However, separator periph-
`ery .76 is compressed during crimping into a substan-
`tially flat layer having a thickness less than 1 mil (0.0254
`mm).
`Button-type battery 40 of this invention is advanta—
`geous over prior art batteries in that separator 72 ex-
`tends into peripheral crimped seal 64 to ensure complete
`separation between anode 42 and cathode 44. Addition-
`ally, button—type battery 40 has a very thin profile clue
`to the reduced material thicknesses as well as the C—
`shaped crimp seal 64.
`Anode 43, cathode 44, electrolyte 46, terminal hous-
`ing members 48 and 54, insulating gasket 62, and separa-
`tor 72 form an integral button-type energy cell unit 80.
`Energy cell unit 80 has a composite first portion 82 and
`a composite second portion 84 intermediate of periph-
`eral seal 64. Button-type battery 40, by virtue of its thin
`profile in combination with its leak resistant C-shaped
`crimp peripheral seal 64, is capable of being deflected
`such that first portion 82 is angled relative to second
`portion 84 without destroying operation of the button-
`type battery or rupturing the fluid-tight peripheral
`crimp seal 64.
`FIGS. 7 and 8 illustrate the bendable button-type
`battery 40 of this invention. Internal angle 0 is defined
`between first portion 82 and second portion 84 of bat-
`tery energy cell 80. According to this invention, first
`portion 82 can be angled relative to second portion 84
`over a wide range of angles 0. Preferably, internal angle
`
`10
`
`15
`
`20
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`25
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`30
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`35
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`45
`
`50
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`55
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`65
`
`6
`0 is in a range from 175° to at least 90°. That is, the first
`portion can be bent from its horizontal position at plane
`94 (i.e., where internal angle 0 is 180° ) through a —45°
`are from horizontal plane 94 (thereby defining an inter—
`nal angle 0 of 135° ), to a perpendicular position (defin-
`ing an internal angle 0 of 90° ). It has been shown in
`experiments that button-type battery 40 can be bent 90"
`without destroying operation of the energy cell or rup-
`turing the fluid-tight primary crimp seal. Test data sup-
`porting this finding is discussed below.
`FIGS. 7 and 8 illustrate button—type battery 40 being
`bent in a downward arc 92 from horizontal plane 94. It
`should be understood that button-type battery 40 can be
`bent in an upward are 96 from horizontal plane 94 with
`similar success. Internal angle 9 would again be the
`angle between first portion 82 and second portion 84.
`The flexibility of button-type batteries of this inven-
`tion is achieved by a combination of the thin profile of
`the battery and the peripheral crimp seal 64. The thick-
`ness of energy cell unit 80 (i.e., the total combined
`thicknesses of anode 42, cathode 44, separator 72, and
`the first and second terminal housing members 48 and
`54) is less than 1 mm, and is most preferably approxi-
`mately 0.5 mm or less. Peripheral crimp seal 64 has an
`effective seal integrity that resists leakage of the electro-
`lyte, while facilitating the thin profile of battery 40.
`In this manner, the energy cell unit 80 has an effective
`thickness and the C-shaped peripheral crimp seal 64 has
`an effective seal integrity to permit flexibility of button-
`type battery 40 where first portion 82 can be deflected
`relative to second portion 84 without destroying opera—
`tion of the button-type battery or rupturing the fluid-g
`tight peripheral crimp seal.
`Comparative deflection analysis was conducted on
`the button-type battery 40 of this invention and conven-
`tional button-type batteries. In two analyses described
`herein, a battery manufactured by Renata SA of Itin-
`gen, Switzerland, was used as a representative conven-
`tional button-type battery. In these two comparative
`analyses, a 2005 battery and a 1605 battery constructed
`according to this invention were examined against a
`2016 battery and a 1620 battery, respectively, manufac-
`tured by Renata TM. The notation “2005” is standard
`and well understood in the battery industry. The first
`two digits “20” represent the battery diameter in milli—
`meters (i.e., “20” means 20 mm) and the second two
`digits “05” represent a thickness of the battery cell in
`tenths of millimeters (i.e., “05” means 0.5 mm). Accord-
`ingly, a 2005 button-type battery has a 20 mm diameter
`and a 0.5 mm thickness and a 1605 button—type battery
`has a 16 mm diameter and a 0.5 mm thickness). The 2016
`Renata TM battery has a 20 mm diameter and a 1.6 mm
`thickness and the 1620 Renata TM battery has a 16 mm
`diameter and a 2.0 mm thickness.
`The data from these comparative tests are found in
`Tables I and II below. The data collected during the
`comparative analysis was derived according to the fol-
`lowing procedure. Each battery was clamped in a vise
`grip along its center maximum diameter and deflected
`about the diameter (as illustrated in FIG. 7). A traveler
`measurement device was inverted and placed against
`the bottom can or first terminal housing member near
`the edge of the battery. Pressure was then applied on
`the opposing side of the battery against the traveler.
`The traveler measured defection, with a sensitivity of
`:1 mil (i.e., 0.001 inches or 0.0254 mm). Pressure was
`then released at the desired deflection amounts and the
`battery cell was observed. Any noticeable rupturing of
`
`JLab/Cambridge, Exh. 1019, p. 9
`
`JLab/Cambridge, Exh. 1019, p. 9
`
`

`

`5,432,027
`
`7
`the cell seal was noted and any residual bend following
`deflection was measured.
`The following Tables I and II show the amount de-
`flected in mils, followed by respective columns of the
`two batteries being compared which show residual
`bends, also in mils. The point of deflection at which the
`Renata TM cell ruptured and the electrolyte material
`leaked out is identified in the tables.
`Table I compares the 2016 Renata TM battery with a
`2005 button-type battery of this invention.
`TABLE I
`
`Residual Bend
`(mils)
`
`Deflection
`2016
`2005
`
` (mils) Renata TM Invention
`
`
`1
`0.1
`0
`2
`0.3
`0
`3
`0.5
`0.1
`4
`1.0
`0.4
`5
`1.1
`0.5
`6
`1.1
`0.6
`7
`1.2
`0.6
`8
`1.3
`0.6
`9
`Ruptured 1.7
`0.8
`10
`2.0
`1.0
`11
`2.2
`1.2
`12
`2.5
`1.2
`13
`2.7
`1.3
`14
`3.0
`1.4
`15
`3.3
`1.5
`16
`3.8
`1.8
`17
`4.2
`2.0
`18
`5.0
`2.1
`19
`6.0
`2.3
`20
`6.4
`2.5
`25
`8.3
`3.1
`
`10.230 4.0
`
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`40
`
`8
`internal angle 0 between the two bend portions of the
`Renata TM battery was only 178.7° at rupture.
`The Renata TM 1620 ruptured at a deflection of 18
`mils. For a battery having a diameter of 16 mm, this
`means the Renata TM 1620 ruptured at an angular de-
`flection about its center of 3.3"; or said another way, the
`internal angle 0 between the two angled portions was
`merely 176.7” at rupture.
`In a third analysis, a button-type battery sold under
`the mark Eveready TM was used as a representative
`conventional button-type battery. The analysis exam-
`ined a 2005 battery of this invention against a 2012
`Eveready TM battery (i.e., having a 20 mm diameter
`and a 1.2 mm thickness). The same procedure as that
`described above was used to conduct the comparison.
`Table III contains the results.
`
`TABLE III
`
`Residual Bend
`(mils)
`
`Deflection
`2012
`2005
`
`(mils)
`Eveready TM
`Invention
`l
`0
`0
`2
`0.3
`0
`3
`0.7
`0.1
`4
`1.0
`0.4
`5
`1.1
`0.5
`6
`1.3
`0.6
`7
`1.8
`0.6
`8
`1.9
`0.6
`9
`2.1
`0.8
`10
`2.3
`1.0
`11
`2.8
`1.2
`12
`3.1
`1.2
`13
`3.5
`1.3
`14
`4.0
`1.4
`15
`4.2
`1.5
`16
`4.8
`1.8
`17
`5.1
`2.0
`18
`5.9
`2.1
`19
`Ruptured 6.1
`2.3
`20
`6.9
`2.5
`25
`8.3
`3.1
`
`9.530 4.0
`
`
`As evident from the data in Table III, the Everea-
`dy TM 2012 battery ruptured and began to leak electro-
`lyte following a deflection of 19 mils (0.4826 mm). The
`Eveready TM 2012 battery ruptured at an angular de-
`flection of 28°; or the internal angle 0 between the two
`bend portions of the Eveready TM battery was only
`1772" at rupture.
`It is clear from these results that conventional button-
`type batteries are incapable of being angled while still
`remaining operational. Again, the Renata TM and To-
`shiba TM batteries are considered to be representative
`of conventional button-type batteries. The 2005 and
`1605 batteries of this invention are the thinnest button-
`type batteries known to be in existence at the time this
`document was drafted. The 2016 and 1620 Renata TM
`batteries represent thin button—type batteries, with the
`2012 Eveready TM battery representing the thinnest
`button-type battery, that were commercially available.
`It should be noted that similar tests and results were also
`achieved in comparative analysis with Toshiba TM but-
`ton-type batteries.
`In striking contrast to conventional button-type bat-
`teries, the button-type battery of this invention did not
`rupture throughout the comparative analyses. The bat-
`tery was further bent beyond the 30 mils indicated in
`Tables I, II, and III until the first portion 82 was essen-
`tially perpendicular to the second portion 84, resulting
`
`JLab/Cambridge, Exh. 1019, p. 10
`
`Table II compares the 1620 Renata TM Battery with 35
`a 1605 button-type battery of this invention.
`TABLE II
`
`Residual Bend
`
`(mils)
`Deflection
`1620
`1605
`(mils)
`Renata TM
`Invention
`
`1
`0.1
`0
`2
`0.3
`0
`3
`0.5
`0
`4
`0.9
`0.1
`5
`1.0
`0.3
`6
`1.1
`0.6
`7
`1.3
`1.0
`8
`1.6
`1.1
`9
`1.9
`1.3
`10
`2.0
`1.3
`11
`2.2
`1.5
`12
`2.8
`1.8
`13
`3.0
`2.2
`14
`3.3
`2.4
`15
`3.8
`2.9
`16
`4.8
`3.1
`17
`5.3
`3.3
`18
`Ruptured 6.0
`3.5
`19
`6.4
`3.8
`20
`6.8
`4.3
`25
`9.0
`6.0
`30
`12.4
`8.2
`60
`
`45
`
`50
`
`55
`
`As evident from the data in Tables I and II, it was
`observed that the Renata TM 2016 battery ruptured and
`began to leak electrolyte following a deflection of 9
`mils. For a battery diameter of 20 mm which is bent 65
`along the center diameter (in a similar fashion as shown
`in FIG. 7), the Renata TM 2016 battery ruptured at an
`angular deflection of 13°; or said another way,
`the
`
`JLab/Cambridge, Exh. 1019, p. 10
`
`

`

`9
`in an internal angle 0 of 90°. At this perpendicular ar—
`rangement, the battery cell was still fully operational
`and the C-shape crimp seal had not ruptured. The cell
`was then bent beyond perpendicular so that the internal
`angle 0 was less than 90°. The battery remained fully 5
`operational until an internal angle 6 of approximately
`40°, at which time the cell shorted and stopped work-
`ing. It is believed that a cell constructed with the
`slightly increased rim separation shown in FIG. 6 can
`be bent beyond an internal angle 0 of 40° without de- 10
`stroying battery operation or rupturing the seal.
`FIG. 6 shows a modified crimp seal section wherein
`seal 64 is radially spaced farther from upper terminal
`housing member 54. The separation distance D5 be—
`tween the radially inward edge of segment 66 of first 15
`terminal housing member 48 and sloping portion 55 of
`second terminal housing member 54 is increased to
`preferably approximately 3 mils (0.0762 mm). By com-
`parison, the width We of the overlapping members 66,
`68 and periphery 58 within crimp seal 64 is approxi-
`mately 7 mils (0.1778 ram). The FIG. 6 modification
`reduces or effectively eliminates any tendency of the
`inward edge of segment 66 to contact second terminal
`housing member 54 during deflection and thereby elec—
`trically short the two terminal housing members to- 25
`gether. Of course, another modification for assuring
`good electrical insulation between housing members 48
`and 54 during flexing is to have insulating gasket mate-
`rial 62 exteriorly extend beyond crimp seal 64 and past
`segment 66, projecting partially up sloping portion 55 of 30
`first terminal housing member 54.
`Apart from deflection, another appreciable difference
`between the button-type battery of this invention and
`conventional button-type batteries concerns the amount
`of force required to effectuate the bend. Comparatively 35
`little force was used to angle the button-type batteries of
`this invention, whereas comparatively greater force
`was required to angle the Renata TM and Eveready TM
`batteries. Table IV lists the amount of force (in kg,
`where l kg=2.2 lbs) applied to each of the five button- 40
`type batteries to achieve a deflection of 10 mils.
`TABLE IV
`
`20
`
`Force Applied to Cause a Deflection of 10 mils
`2012
`2016
`1605
`Eveready TM
`Renata TM
`Invention
`1.8 kg
`3.4 kg
`0.3 kg
`
`1620
`Renata TM
`>6.0 kg
`
`2005
`Invention
`<0.2 kg
`
`The bendable button-type battery 40 of this invention
`is advantageous for two reasons. First, it is very thin. At
`0.5 mm, the battery 40 of this invention is over twice as
`thin in comparison to presently commercial button-type
`batteries which have a minimum thickness of 1.2 mm.
`This thin profile is advantageous for application in thin
`integrated circuit cards. Credit cards and the like have
`a nominal thickness requirement of 30 mils (0.762 mm).
`The 0.5 mm button-type battery of this invention satis-
`fies this requirement for credit cards, whereas the pres-
`ent commercial button-type batteries at 1.2 mm are too
`thick.
`
`The second advantage is that the bendable button—
`type battery of this invention is ideal for use in credit
`cards or smart cards which have certain flexibility re-
`quirements. Once installed in a credit card, button-type
`battery 40 can be flexed with the credit card without
`danger of becoming inoperable. Prior art button—type
`batteries have essentially no flexibility and rupture im-
`mediately when even slightly bent.
`
`45
`
`50
`
`55
`
`60
`
`65
`
`5,432,027
`
`10
`In compliance with the statute, the invention has been
`described in language more or less specific as to struc-
`tural and methodical features. It is to be understood,
`however, that the invention is not limited to the specific
`features shown and described, since the means herein
`disclosed comprise preferred forms of putting the in—
`vention into effect. The invention is, therefore, claimed
`in any of its forms or modifications within the proper
`scope of the appended claims appropriately interpreted
`in accordance with the doctrine of equivalents.
`We claim:
`
`1. A button cell comprising:
`an anode;
`_
`a cathode positioned adjacent to the anode;
`a