The present invention is directed to the fabrication of thin aluminum anode batteries using a highly reproducible process that enables high volume manufacturing of the galvanic cells. A method of fabricating a thin aluminum anode galvanic cell is provided, the method comprising, forming a recess in the silicon wafer, the recess having no more than three sidewalls, depositing a catalytic metal layer on a bottom surface of the recess, positioning a double-side sticky tape layer having a bottom side positioned to contact the no more than three sidewalls of the recess and positioning an aluminum foil layer to contact a top side of the double-side sticky tape layer and in overlying relation to the recess, thereby forming the galvanic cell.
Cardenas-Valencia, Andres M.; Dlutowski, Jay; Calves, Melynda C.; Bumgarner, John; and Langebrake, Larry, "Method for the fabrication of electrolyte cavities using bulk micro-machining" (2014). USF Patents. 108.
University of South Florida