Methods for making device enclosures and devices with an integrated battery

• US 20060021214A1
• Filed: 09/21/2005
• Published: 02/02/2006
• Est. Priority Date: 03/24/2000
• Status: Abandoned Application

• Current Assignee: Jenn-Feng Yan, Jody Jon Klaassen, Mark Lynn Jenson, Victor Henry Weiss
• Original Assignee: Jenn-Feng Yan, Jody Jon Klaassen, Mark Lynn Jenson, Victor Henry Weiss
• Inventors: Yan, Jenn-Feng, Klaassen, Jody Jon, Jenson, Mark Lynn, Weiss, Victor Henry
• Application Number:
  US11/233,157
• Publication Number:
  US 20060021214A1
• Time in Patent Office: Days
• US Class Current: 29/623.100
• 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

An electrically powered device includes a shell, and a battery integrated with the shell. The electrically powered device also includes a trace, and a site adapted to receive an electrically powered component, wherein the battery, the trace and the electrically powered component form a portion of a circuit. The electrically shell may be a portion of an enclosure. The battery is formed within the shell and may be comprised of one or a plurality of deposited layers.

Claims

1. A method to fabricate a device, the method comprising:

providing a first substrate that will form a portion of a shell enclosure for an electrically powered apparatus;

depositing a first conductive layer on a first surface area of the first substrate;

fabricating a thin-film battery by depositing a cathode film in electrical contact with the first conductive layer;

depositing an anode film in electrical contact with a second conductive layer; and

forming an electrolyte layer in contact with and completely separating the anode film and the cathode film; and

forming the first substrate into a shape having a concave interior surface and a convex exterior surface and configured to be the portion of the shell enclosure.

2. The method of claim 1, wherein the providing of the first substrate, the depositing of the first conductive layer, the fabricating of the battery and the forming of the first substrate are performed in the order indicated.

3. The method of claim 1, wherein the providing of the first substrate further includes depositing the second conductive layer on a second surface area of the first substrate.

4. The method of claim 3, further comprising folding the first substrate upon itself.

5. The method of claim 1, wherein the depositing of the cathode film includes depositing a lithium intercalation material.

6. The method of claim 1, wherein the depositing of the anode film includes depositing a lithium intercalation material and the depositing of the cathode film includes depositing a lithium intercalation material.

7. The method of claim 1, wherein the depositing of the anode film includes depositing a lithium intercalation material.

8. The method of claim 1, wherein the depositing of the anode film includes depositing lithium metal.

9. The method of claim 1, wherein the fabricating of the battery comprises depositing a lithium phosphorus oxynitride as at least part of the electrolyte layer, wherein the electrolyte layer is in contact with and completely separates the anode film and the cathode film, and wherein the cathode film includes an intercalation material.

10. The method of claim 1, wherein the fabricating of the battery further comprises fabricating the battery on the first shell after the forming of the substrate into the shape of the shell enclosure.

11. The method of claim 10, wherein the fabricating of the battery further comprises fabricating the battery on the interior surface.

12. The method of claim 10, wherein the fabricating of the battery further comprises sputtering the battery on the exterior surface.

13. The method of claim 1, wherein the fabricating of the battery further comprises placing a protective layer over the battery.

14. The method of claim 1, further comprising:

forming a trace;

forming a site adapted to receive an electrically powered component; and

connecting the battery, the trace, and the electrically powered component into at least a portion of a circuit.

15. The method of claim 1, wherein the forming includes rolling the first substrate to form the shell.

16. A method to fabricate a device, the method comprising:

providing a first substrate that will form a portion of a rolled apparatus enclosure for an electrically powered apparatus;

depositing a first conductive layer on a first surface area of the first substrate;

fabricating a battery by depositing a cathode film in electrical contact with the first conductive layer;

depositing an anode film in electrical contact with a second conductive layer; and

forming an electrolyte layer in contact with and completely separating the anode film and the cathode film; and

rolling the first substrate into a shape configured to be the portion of the rolled apparatus enclosure.

17. The method of claim 16, wherein the rolling the first substrate further includes rolling the first substrate upon itself.

18. The method of claim 16, wherein the rolling the first substrate further includes rolling the first substrate around an electrical motor that is electrically coupled to the battery and wherein the electrical motor includes a shaft operatively coupled to the motor and a chuck placed upon the shaft to form a hand-held drill for homeowner use.

19. The method of claim 16, wherein the rolling the first substrate further includes rolling the first substrate and coupling an LED light to the battery to form a flashlight.

20. A method to fabricate a device, the method comprising:

providing a substrate that will form a portion of a shell enclosure for an electrically powered apparatus;

depositing a first conductive layer on a first surface area of the substrate and a second conductive layer on a second surface area of the substrate;

fabricating a battery by depositing a cathode film in electrical contact with the first conductive layer;

depositing an anode film in electrical contact with the second conductive layer; and

forming an electrolyte layer in contact with and completely separating the anode film and the cathode film, wherein the electrolyte layer includes LiPON; and

forming the substrate into a shape having a concave interior surface and a convex exterior surface and configured to be the portion of the shell enclosure.

21. The method of claim 20, wherein the providing of the substrate, the depositing of the first conductive layer, the fabricating of the battery and the forming of the substrate are performed in the order indicated.

22. The method of claim 20, further comprising folding the substrate upon itself.

23. The method of claim 20, wherein the providing of the substrate, the depositing of the first conductive layer, the fabricating of the battery and the rolling of the substrate are performed in the order indicated.

24. The method of claim 20, wherein the depositing of the cathode film includes depositing a lithium intercalation material.