Method and apparatus for integrated-battery devices

• US 20010033952A1
• Filed: 03/23/2001
• Published: 10/25/2001
• Est. Priority Date: 03/24/2000
• Status: Active Grant

• Current Assignee: Cymbet Corporation
• Original Assignee: Integrated Power Solutions, Inc.
• Inventors: Klaassen, Jody Jon, Jenson, Mark Lynn
• Granted Patent: US 6,805,998 B2
• Time in Patent Office: Days
• US Class Current: 429/7
• CPC Class Codes: A61N 1/3787 from an external energy source
• CPC Class Codes: C23C 14/0031 Bombardment of substrates by reactive ion beams
• CPC Class Codes: C23C 14/0676 Oxynitrides
• CPC Class Codes: C23C 14/08 Oxides C23C14/10 takes precedence
• CPC Class Codes: C23C 16/047 using irradiation by energy or particles
• CPC Class Codes: G02F 1/13306 Circuit arrangements or driving methods for the control of single liquid crystal cells G02F1/132, G02F1/133382 take precedence
• CPC Class Codes: G02F 1/13324 Circuits comprising solar cells
• CPC Class Codes: H01G 11/08 Structural combinations, e.g. assembly or connection, of hybrid or EDL capacitors with other electric components, at least one hybrid or EDL capacitor being the main component
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/56 Solid electrolytes, e.g. gels; Additives therein
• CPC Class Codes: H01L 2224/16225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/49109 outside the semiconductor or solid-state body
• CPC Class Codes: H01L 23/58 Structural electrical arrangements for semiconductor devices not otherwise provided for , e.g. in combination with batteries H01L23/49593, H01L23/49596 take precedence
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/09701 Low temperature co-fired ceramic [LTCC]
• CPC Class Codes: H01L 2924/10253 Silicon [Si]
• CPC Class Codes: H01L 2924/12044 OLED
• CPC Class Codes: H01L 31/073 comprising only AIIBVI compound semiconductors, e.g. CdS/CdTe solar cells
• CPC Class Codes: H01L 31/1828 : the active layers comprising only AIIBVI compounds, e.g. CdS, ZnS, CdTe
• CPC Class Codes: H01M 10/0436 : Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0472 : Vertically superposed cells with vertically disposed plates
• CPC Class Codes: H01M 10/052 : Li-accumulators
• CPC Class Codes: H01M 10/0525 : Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/0562 : Solid materials
• CPC Class Codes: H01M 10/058 : Construction or manufacture
• CPC Class Codes: H01M 10/0585 : of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 10/42 : Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• CPC Class Codes: H01M 10/425 : Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/4257 : Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/4264 : with capacitors
• CPC Class Codes: H01M 10/44 : Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/46 : Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/465 : with solar battery as charging system
• CPC Class Codes: H01M 14/00 : Electrochemical current or voltage generators not provided for in groups H01M6/00 - H01M12/00; Manufacture thereof
• CPC Class Codes: H01M 14/005 : Photoelectrochemical storage cells light sensitive devices H01G9/20, semiconductors sensitive to light H01L31/00
• CPC Class Codes: H01M 2004/021 : Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2008/1293 : Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 4/0421 : involving vapour deposition
• CPC Class Codes: H01M 4/0423 : Physical vapour deposition
• CPC Class Codes: H01M 4/0426 : Sputtering
• CPC Class Codes: H01M 4/1391 : of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1393 : of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/1397 : of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
• CPC Class Codes: H01M 4/382 : Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/405 : Alloys based on lithium
• CPC Class Codes: H01M 4/483 : for non-aqueous cells H01M4/485 takes precedence
• CPC Class Codes: H01M 4/581 : Chalcogenides or intercalation compounds thereof
• CPC Class Codes: H01M 4/5825 : Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 4/587 : for inserting or intercalating light metals
• CPC Class Codes: H01M 4/8885 : Sintering or firing
• CPC Class Codes: H01M 4/9016 : Oxides, hydroxides or oxygenated metallic salts
• CPC Class Codes: H01M 50/103 : prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/403 : Manufacturing processes of separators, membranes or diaphragms
• CPC Class Codes: H01M 6/185 : with oxides, hydroxides or oxysalts as solid electrolytes
• CPC Class Codes: H01M 6/186 : Only oxysalts-containing solid electrolytes
• CPC Class Codes: H01M 6/188 : Processes of manufacture
• CPC Class Codes: H01M 6/40 : Printed batteries , e.g. thin film batteries
• CPC Class Codes: H01M 6/42 : Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H01M 8/1007 : with both reactants being gaseous or vaporised H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1286 : Fuel cells applied on a support, e.g. miniature fuel cells deposited on silica supports
• CPC Class Codes: H04M 1/0262 : for a battery compartment
• CPC Class Codes: H05K 1/16 : incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• CPC Class Codes: Y02E 10/543 : Solar cells from Group II-VI materials
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10S 117/902 : Specified orientation, shape, crystallography, or size of seed or substrate
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/5313 : Means to assemble electrical device
• CPC Class Codes: Y10T 29/53135 : Storage cell or battery

Abstract

A combined battery and device apparatus and associated method. This apparatus includes a first conductive layer, a battery comprising a cathode layer; an anode layer, and an electrolyte layer located between and electrically isolating the anode layer from the cathode layer, wherein the anode or the cathode or both include an intercalation material, the battery disposed such that either the cathode layer or the anode layer is in electrical contact with the first conductive layer, and an electrical circuit adjacent face-to-face to and electrically connected to the battery. Some embodiments further include a photovoltaic cell. In some embodiments, the substrate includes a polymer having a melting point substantially below 700 degrees centigrade. In some embodiments, the substrate includes a glass. For example, some embodiments include a battery deposited directly on the back of a liquid-crystal display (LCD) device.

Claims

1. A combined battery and device apparatus comprising:

a first structure including;

a first conductive layer;

a battery including a cathode layer;

an anode layer, and an electrolyte layer located between and electrically isolating the anode layer from the cathode layer, wherein the anode or the cathode or both include an intercalation material, the battery disposed such that either the cathode layer or the anode layer is in electrical contact with the first conductive layer, and

an electrical circuit having a major surface adjacent face-to-face to and electrically connected to the battery.

2. The apparatus according to

claim 1

, further comprising:

a photovoltaic cell having a major surface adjacent face-to-face to the first structure; and

an integrated circuit operatively coupled to charge the battery using current from the photovoltaic cell.

3. The apparatus according to

claim 1

, further comprising a photovoltaic cell having a major surface adjacent face-to-face to a surface of the battery.

4. The apparatus according to

claim 1

, further comprising:

a substrate, the battery having a major surface adjacent face-to-face to the substrate; and

a photovoltaic cell having a major surface adjacent face-to-face to a surface of the substrate beside the battery.

5. The apparatus according to

claim 1

, further comprising:

a substrate, the battery having a major surface adjacent face-to-face to the substrate; and

a photovoltaic cell having a major surface adjacent face-to-face to an opposite face surface of the substrate from the battery.

6. The apparatus according to

claim 1

, wherein the electrical circuit comprises:

a photovoltaic cell having a major surface adjacent face-to-face to the battery; and

a charging circuit supported on the photovoltaic cell and electrically coupled to charge the battery using current from the photovoltaic cell.

7. The apparatus according to

claim 1

, wherein the electrical circuit includes a thin-film capacitor adjacent to the battery.

8. The apparatus according to

claim 1

, wherein the electrical circuit includes:

a thin-film capacitor adjacent to the battery; and

an integrated circuit mounted on the capacitor and electrically connected to the battery and the capacitor.

9. The apparatus according to

claim 1

, wherein the electrical circuit includes:

an insulating layer adjacent to the battery; and

a plurality of electrical traces adjacent to the insulating layer, wherein at least one of the plurality of electrical traces contacts an electrode of the battery through the insulating layer.

10. The apparatus according to

claim 1

, the electrical circuit further comprising:

an insulating layer adjacent to the battery;

a plurality of electrical traces adjacent to the insulating layer; and

an integrated circuit supported on the battery, wherein a first one of the plurality of electrical traces electrically connects the cathode of the battery and the integrated circuit, a second one of the plurality of electrical traces electrically connects the anode of the battery and the integrated circuit.

11. The apparatus according to

claim 1

, the substrate further comprising:

an integrated circuit; and

an insulating layer adjacent to the integrated circuit, the insulating layer including a plurality of through vias, wherein the battery is adjacent to the insulating layer, wherein the cathode of the battery electrically connects to the integrated circuit though a first one of plurality of through vias, and the anode of the battery electrically connects to the integrated circuit though a second one of plurality of through vias.

12. The apparatus according to

claim 1

, the substrate further comprising:

an integrated circuit; and

an insulating layer adjacent to the integrated circuit, the insulating layer including a plurality of through vias, wherein a cathode-conductor of the battery is adjacent to the insulating layer and electrically connects to the integrated circuit though a first one of plurality of through vias, the cathode layer of the battery is adjacent to the cathode conductor, the electrolyte layer is adjacent to the cathode layer, and the anode is adjacent to the electrolyte layer and electrically connects to the integrated circuit though a second one of plurality of through vias.

13. The apparatus according to

claim 1

, the substrate further comprising:

an integrated circuit; and

an insulating layer adjacent to the integrated circuit, the insulating layer including a plurality of through vias, wherein a cathode-conductor of the battery is adjacent to a face of the integrated circuit opposite the insulating layer and electrically connects to the integrated circuit though a first one of plurality of through vias, the cathode layer of the battery is adjacent to the cathode conductor, the electrolyte layer is adjacent to the cathode layer, and the anode is adjacent to the electrolyte layer and electrically connects to the integrated circuit though a second one of plurality of through vias.

14. The apparatus according to

claim 1

, the electrical circuit further comprising:

an insulating layer adjacent to the battery that acts as a passivation layer that protects the anode from environmental corrosion; and

a plurality of electrical traces adjacent to the insulating layer, wherein at least one of the plurality of electrical traces contacts an electrode of the battery through the insulating layer.

15. The apparatus according to

claim 1

, wherein the substrate has a curved shape having a convex face and a concave face, and the battery is located on the concave face.

16. The apparatus according to

claim 1

, wherein the substrate comprises a polymer having a melting point substantially below 700 degrees centigrade.

17. The apparatus according to

claim 1

, wherein the substrate comprises a metal foil.

18. The apparatus according to

claim 1

, wherein the substrate comprises a metal foil having an insulative layer between the metal foil and the first conductive layer adjacent to a first surface area of the substrate'"'"'s major surface area.

19. The apparatus according to

claim 1

, wherein the substrate comprises a ceramic.

20. The apparatus according to

claim 1

, wherein the substrate comprises a glass.

21. A method for making a combined battery and device apparatus, the method comprising:

providing a substrate having a major surface area;

depositing a first conductive layer on a first surface area of the substrate'"'"'s major surface area;

depositing onto the first conductive layer a battery including a cathode layer;

an anode layer, and a electrolyte layer located between and electrically isolating the anode layer from the cathode layer, wherein the anode or the cathode or both include an intercalation material, the battery disposed such that either the cathode layer or the anode layer is in electrical contact with the first conductive layer; and

depositing an electrical circuit on the battery.

22. The method according to

claim 21

, further comprising:

depositing a photovoltaic cell on the first structure;

attaching an integrated circuit to the first structure; and

operatively coupling the integrated circuit to charge the battery using current from the photovoltaic cell.

23. The method according to

claim 21

, further comprising depositing a photovoltaic cell on a surface of the battery.

24. The method according to

claim 21

, further comprising depositing a photovoltaic cell on a surface of the substrate beside the battery.

25. The method according to

claim 21

, further comprising depositing a photovoltaic cell on an opposite face surface of the substrate from the battery.

26. The method according to

claim 21

, wherein depositing the electrical circuit comprises:

depositing a photovoltaic cell on the battery;

supporting a charging circuit on the photovoltaic cell; and

electrically coupling the charging circuit to charge the battery using current from the photovoltaic cell.

27. The method according to

claim 21

, further comprising depositing a thin-film capacitor on the battery.

28. The method according to

claim 21

, wherein depositing the electrical circuit comprises:

depositing a thin-film capacitor on the battery;

mounting an integrated circuit on the capacitor; and

electrically connecting the integrated circuit to the battery and the capacitor.

29. The method according to

claim 21

, further comprising:

depositing an insulating layer on the battery; and

depositing a plurality of electrical traces on the insulating layer, wherein at least one of the plurality of electrical traces contacts an electrode of the battery through the insulating layer.

30. The method according to

claim 21

, further comprising:

depositing an insulating layer on the battery;

depositing a plurality of electrical traces on the insulating layer;

supporting an integrated circuit on the battery;

electrically connecting a first one of the plurality of electrical traces to the cathode of the battery and the integrated circuit; and

electrically connecting a second one of the plurality of electrical traces to the anode of the battery and the integrated circuit.

31. The method according to

claim 21

, wherein the substrate includes an integrated circuit, the method further comprising:

depositing an insulating layer on the integrated circuit, the insulating layer including a plurality of through vias, wherein the battery is adjacent to the insulating layer;

electrically connecting the cathode of the battery to the integrated circuit though a first one of plurality of through vias; and

electrically connecting the anode of the battery to the integrated circuit though a second one of plurality of through vias.

32. The method according to

claim 21

, wherein the substrate includes an integrated circuit, the method further comprising:

depositing an insulating layer adjacent to the integrated circuit, the insulating layer including a plurality of through vias;

depositing a cathode-conductor of the battery on the insulating layer;

electrically connecting the cathode-conductor of the battery to the integrated circuit though a first one of plurality of through vias;

depositing the cathode layer of the battery on the cathode conductor;

depositing the electrolyte layer on the cathode layer;

depositing the anode on the electrolyte layer; and

electrically connecting the anode to the integrated circuit though a second one of plurality of through vias.

33. The method according to

claim 21

, wherein the substrate includes an integrated circuit, the method further comprising:

depositing an insulating layer on the integrated circuit, the insulating layer including a plurality of through vias;

depositing a cathode-conductor of the battery on a face of the integrated circuit opposite the insulating layer;

electrically connecting the cathode-conductor of the battery to the integrated circuit though a first one of plurality of through vias;

depositing the cathode layer of the battery on the cathode conductor;

depositing the electrolyte layer on the cathode layer;

depositing the anode on the electrolyte layer; and

electrically connecting the anode to the integrated circuit though a second one of plurality of through vias.

34. The method according to

claim 21

, further comprising:

depositing an insulating layer on the battery that acts as a passivation layer that protects the anode from environmental corrosion;

depositing a plurality of electrical traces on the insulating layer, wherein at least one of the plurality of electrical traces contacts an electrode of the battery through the insulating layer.

35. The method according to

claim 21

, further comprising:

forming the substrate into a curved shape having a convex face and a concave face; and

locating the battery on the concave face.

36. The method according to

claim 21

, wherein the substrate comprises a polymer having a melting point substantially below 700 degrees centigrade.

37. The method according to

claim 21

, wherein the substrate comprises a metal foil.

38. The method according to

claim 21

, wherein the substrate comprises a metal foil having an insulative layer between the metal foil and the first conductive layer is deposited on a first surface area of the substrate'"'"'s major surface area.

39. The method according to

claim 21

, wherein the substrate comprises a ceramic material.

40. The method according to

claim 21

, wherein the substrate comprises a glass material.

41. The method according to

claim 21

, wherein the depositing of the battery comprises:

depositing the cathode layer onto the first conductive layer;

depositing the electrolyte layer onto the cathode layer; and

depositing the anode material onto the electrolyte layer.

42. The method according to

claim 41

, wherein the depositing of the battery comprises depositing the cathode layer onto the first conductive layer and annealing a surface of the cathode material to a temperature higher than that of the electrical circuit underlying the cathode layer.

43. The method according to

claim 41

, wherein the depositing of the battery comprises depositing the electrolyte layer onto the first conductive layer and annealing a surface of the electrolyte layer material to a temperature higher than that of the electrical circuit underlying the electrolyte layer.

44. A method for making a combined battery and device apparatus, the method comprising:

providing an electrical circuit having a major surface area and having a first conductive layer on a first surface area of the electrical circuit'"'"'s major surface area; and

depositing onto the first conductive layer a battery comprising a cathode layer;

an anode layer, and a electrolyte layer located between and electrically isolating the anode layer from the cathode layer, the battery disposed such that either the cathode layer or the anode layer is in electrical contact with the first conductive layer, wherein the anode or the cathode or both include an intercalation material.

45. The method according to

claim 44

, wherein the depositing of the battery comprises:

depositing the cathode layer onto the first conductive layer;

depositing the electrolyte layer onto the cathode layer; and

depositing the anode material onto the electrolyte layer.

46. The method according to

claim 45

, wherein the depositing of the battery comprises:

depositing the cathode layer onto the first conductive layer and annealing a surface of the cathode material to a temperature higher than that of the electrical circuit underlying the cathode layer.

47. The method according to

claim 45

, wherein the depositing of the battery comprises:

depositing the electrolyte layer onto the first conductive layer and annealing a surface of the electrolyte layer material to a temperature higher than that of the electrical circuit underlying the electrolyte layer.

48. A combined battery and device apparatus comprising:

a first structure including;

a substrate having a major surface area;

a first conductive layer adjacent to a first surface area of the substrate'"'"'s major surface area;

a battery comprising a cathode layer;

an anode layer, and a electrolyte layer located between and electrically isolating the anode layer from the cathode layer, the battery disposed such that either the cathode layer or the anode layer is in electrical contact with the first conductive layer, wherein the anode or the cathode or both include an intercalation material; and

an electrical circuit adjacent to and electrically connected to the battery.

49. The apparatus according to

claim 48

, further comprising:

a photovoltaic cell adjacent to the first structure; and

an integrated circuit operatively coupled to charge the battery using current from the photovoltaic cell.

50. The apparatus according to

claim 48

, further comprising a photovoltaic cell adjacent to a surface of the battery.

51. The apparatus according to

claim 48

, further comprising a photovoltaic cell adjacent to a surface of the substrate beside the battery.

52. The apparatus according to

claim 48

, further comprising a photovoltaic cell adjacent to an opposite face surface of the substrate from the battery.

53. The apparatus according to

claim 48

, wherein the electrical circuit comprises:

a photovoltaic cell adjacent to the battery; and

a charging circuit supported on the photovoltaic cell and electrically coupled to charge the battery using current from the photovoltaic cell.

54. The apparatus according to

claim 48

, wherein the electrical circuit includes a thin-film capacitor adjacent to the battery.

55. The apparatus according to

claim 48

, wherein the electrical circuit includes:

a thin-film capacitor adjacent to the battery; and

an integrated circuit mounted on the capacitor and electrically connected to the battery and the capacitor.

56. A combined battery and device apparatus comprising:

a substrate;

first conductive layer adjacent face-to-face to the substrate;

a battery having a plurality of layers including;

a cathode layer;

an anode layer; and

an electrolyte layer located between and electrically isolating the anode layer from the cathode layer, wherein the anode or the cathode or both include an intercalation material, the battery disposed such that either the cathode layer or the anode layer is in electrical contact with the first conductive layer; and

an electrical circuit adjacent face-to-face to the substrate;

wherein the electrical circuit has a plurality of layers, and one of the plurality of layers of the electrical circuit and one of the plurality of layers of the battery have substantially identical thicknesses, chemical composition and material characteristics.

57. The apparatus according to

claim 56

, wherein two or more of the plurality of layers of the electrically powered device have a composition substantially identical to and a thickness substantially identical to two or more respective layers of the plurality of layers of the battery.

58. The apparatus according to

claim 56

, wherein the anode includes a lithium-intercalation material.

59. The apparatus according to

claim 56

, wherein the cathode includes a lithium-intercalation material.

60. The apparatus according to

claim 56

, wherein the solid-state electrolyte layer includes a LiPON material.

61. The apparatus according to

claim 56

, wherein the anode includes a lithium-intercalation material, the cathode includes a lithium-intercalation material, and the solid-state electrolyte layer includes a LiPON material.

62. A method for making a combined battery and electrically powered device, the method comprising:

providing a substrate having a major surface area;

depositing a plurality of layers of the battery on a first surface area of the substrate'"'"'s major surface area, wherein the plurality of layers of the battery include a cathode layer;

an anode layer, and a solid-state electrolyte layer located between and electrically isolating the anode layer from the cathode layer, wherein the anode or the cathode or both include an intercalation material or a metal or both; and

depositing a plurality of layers of the electrically powered device on a first surface area of the substrate'"'"'s major surface area, wherein one of the plurality of layers of the electrically powered device has a composition substantially identical to and is deposited substantially simultaneously with one of the plurality of layers of the battery.

63. The method according to

claim 62

, wherein two or more of the plurality of layers of the electrically powered device have a composition substantially identical to and are deposited substantially simultaneously with two or more respective layers of the plurality of layers of the battery.

64. The method according to

claim 62

, wherein the anode includes a lithium-intercalation material.

65. The method according to

claim 62

, wherein the cathode includes a lithium-intercalation material.

66. The method according to

claim 62

, wherein the solid-state electrolyte layer includes a LiPON material.

67. The method according to

claim 62

, wherein the anode includes a lithium-intercalation material, the cathode includes a lithium-intercalation material, and the solid-state electrolyte layer includes a LiPON material.