Integrated Electronic Device and Methods of Making the Same

• US 20100196744A1
• Filed: 07/18/2008
• Published: 08/05/2010
• Est. Priority Date: 07/18/2007
• Status: Active Grant

• Current Assignee: Blue Spark Innovations LLC
• Original Assignee: Blue Spark Technologies, Inc.
• Inventors: Allison, Leonard Blaine, Tucholski, Gary R.
• Granted Patent: US 8,441,411 B2
• Time in Patent Office: Days
• US Class Current: 429/7
• CPC Class Codes: G06K 19/0702 the arrangement including a battery
• CPC Class Codes: G06K 19/07718 the record carrier being manufactured in a continuous process, e.g. using endless rolls
• CPC Class Codes: G06K 19/07749 the record carrier being capable of non-contact communication, e.g. constructional details of the antenna of a non-contact smart card
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49018 with other electrical component

Abstract

An integrated electronic device, and its method of manufacture, are provided. The integrated electronic device can include an electronic assembly, such as an active RFID assembly, that is electrically coupled to a thin printed flexible electrochemical cell. In one example, the electronic assembly and the electrochemical battery are provided on a single substrate. In one example method of manufacture, the entire cell to be made on a printing press to integrate the battery directly with the electronic assembly.

Claims

1. A method of manufacturing an active RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:

providing a first substrate and a second substrate, at least one of which includes a plurality of layers, said first substrate including a first side and a second side;

providing an active RFID assembly on said second side of said first substrate, including a RFID antenna, an active RFID element in communication with the RFID antenna, and a plurality of electrical contacts in electrical communication with the active RFID element;

providing a cathode layer on said first side of said first substrate;

providing an anode layer on said first side of said first substrate;

providing an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer;

providing a frame on said first side of said first substrate to form an inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space;

electrically coupling the cathode layer, the anode layer, and the plurality of electrical contacts; and

connecting said second substrate to said first substrate to substantially seal said inner space containing said cathode layer, said anode layer, and said electrolyte layer.

2. The method of claim 1, wherein at least one of the first substrate and the second substrate includes a web having a plurality of layers.

3. The method of claim 1, wherein the step of providing an active RFID assembly further includes the steps of (i) providing an active RFID element on said second side of said first substrate;

and (ii) printing an RFID antenna and a plurality of electrical contacts on said second side of said first substrate so as to be in electrical contact with said active RFID element, wherein each of said RFID antenna and plurality of electrical contacts include a cured or dried ink.

4. The method of claim 1, wherein the step of electrically coupling the cathode layer, anode layer, and the plurality of electrical contacts further includes the steps of (i) providing a plurality of apertures extending through said first substrate so as to be in communication with each of the cathode layer, anode layer, and the plurality of electrical contacts;

and (2) filling each of said plurality of apertures with a conductive ink for providing said electrical communication between the cathode layer, anode layer, and the plurality of electrical contacts.

5. The method of claim 4, wherein said conductive ink of said plurality of apertures includes at least one of silver and copper.

6. The method of claim 1, further including the step of providing the frame as a third substrate including a web having a plurality of laminated layers, wherein at least one of said laminated layers is a pressure-sensitive adhesive.

7. The method of claim 6, further including the step of providing cutout cavity extending through said third substrate and oriented so as to be in communication with at portion of said cathode layer and a portion of said anode layer.

8. The method of claim 1, further including the step of providing a frame sealant disposed on said first substrate generally bounding a perimeter of said inner space, and wherein said frame sealant is interposed between said first substrate and said frame.

9. The method of claim 1, further comprising the steps of providing a plurality cathode layers and a plurality of anode layers, and electrically connecting said plurality of cathode layers and anode layers together to form a battery.

10. The method of claim 1, further including the step of providing one or both of (1) a cathode collector layer between said cathode layer and said first substrate;

and (2) an anode collector layer between said anode layer and said first substrate.

17. The device of claim 1, wherein said electrical coupler assembly includes a plurality of apertures extending through said first substrate, the plurality of apertures being in communication with each of the cathode layer, anode layer, and the plurality of electrical contacts.

18. The device of claim 17, wherein each of said plurality of apertures are filled with a conductive ink for providing said electrical communication between the cathode layer, anode layer, and the plurality of electrical contacts.

19. The device of claim 18, wherein said conductive ink of said plurality of apertures includes at least one of silver and copper.

11. A method of manufacturing an active RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:

providing a first substrate and a second substrate, at least one of which includes a web having a plurality of layers, said first substrate including a first side and a second side;

providing an active RFID assembly on said second side of said first substrate, including the steps of (i) providing an active RFID element on said second side of said first substrate; and

(ii) printing an RFID antenna and a plurality of electrical contacts on said second side of said first substrate so as to be in electrical contact with said active RFID element, wherein each of said RFID antenna and plurality of electrical contacts include a cured or dried ink;

printing a cathode collector layer on said first side of said first substrate;

printing a cathode layer on said first side of said first substrate;

laminating an anode layer on said first side of said first substrate;

providing an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer;

providing a frame on said first side of said first substrate to form an inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space;

electrically coupling the cathode layer via the cathode collector, the anode layer, and the plurality of electrical contacts; and

connecting said second substrate to said first substrate to substantially seal said inner space containing said cathode layer, said anode layer, and said electrolyte layer.

12. The method of claim 11, wherein the step of electrically coupling the cathode layer, anode layer, and the plurality of electrical contacts further includes the steps of (i) providing a plurality of apertures extending through said first substrate so as to be in communication with each of the cathode layer, anode layer, and the plurality of electrical contacts;

and (2) filling each of said plurality of apertures with a conductive ink for providing said electrical communication between the cathode layer, anode layer, and the plurality of electrical contacts.

13. The method of claim 11, further including the step of providing the frame as a third substrate including a web having a plurality of laminated layers, wherein at least one of said laminated layers is a pressure-sensitive adhesive.

14. The method of claim 13, further including the step of providing a cutout cavity extending through said third substrate and oriented so as to be in communication with at portion of said cathode layer and a portion of said anode layer.

15. The method of claim 11, further comprising the steps of providing a plurality cathode layers and a plurality of anode layers, and electrically connecting said plurality of cathode layers and anode layers together to form a battery.

16. An active RFID device including a flat electrochemical cell for generating an electrical current, said active RFID device including:

a first substrate including of a plurality of laminated layers and defining a first side and a second side;

a second substrate;

an active RFID assembly provided on said second side of said first substrate, including a RFID antenna, an active RFID element in communication with the RFID antenna, and a plurality of electrical contacts in electrical communication with the active RFID element;

a cathode layer provided on said first side of said first substrate;

an anode layer provided on said first side of said first substrate;

an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer;

a frame interposed between said first and second substrate to connect and seal said first substrate to said second substrate to form an inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space, wherein at least one of said anode layer and said cathode layer include a cured or dried ink; and

an electrical coupler assembly providing electrical communication between the cathode layer, the anode layer, and the plurality of electrical contacts.

20. The device of claim 16, wherein said frame is a third substrate including of a plurality of laminated layers and a cutout cavity extending therethrough in communication with at portion of said cathode layer and a portion of said anode layer, wherein at least one of said laminated layers is a pressure-sensitive adhesive.

21. The device of claim 16, wherein at least one of said RFID antenna and said plurality of electrical contacts include a cured or dried ink.

22. The device of claim 16, wherein said frame is a frame sealant disposed on said first substrate generally bounding a perimeter of said inner space, and wherein said frame sealant is interposed between said first substrate and said frame spacer.

23. The device of claim 16, wherein only one of said cathode layer and said anode layer is comprised of a dried or cured ink, and wherein the other of said cathode layer and said anode layer is comprised of a strip of material.

24. The device of claim 16, further comprising a plurality said cathode layers and said anode layers electrically connected together to form a battery.

25. The device of claim 16, wherein one or both of (1) a cathode collector layer is provided between said cathode layer and said first substrate;

and (2) an anode collector layer is provided between said anode layer and said first substrate.

26. A method of manufacturing an active RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:

providing a first substrate including a first side and a second side;

providing an active RFID assembly on said second side of said first substrate;

providing a cathode collector layer on said first side of said first substrate;

providing a cathode layer on said first side of said first substrate;

providing an anode layer on said first side of said first substrate;

providing an electrolyte layer in contact with said cathode layer and also in contact with said anode layer; and

electrically coupling the cathode layer via the cathode collector layer, the anode layer, and the active RFID assembly through the first substrate.

27. The method of claim 26, wherein said first substrate is provided as a generally continuous web from a source station, wherein the steps of providing said cathode layer, providing said anode layer, and electrically coupling the cathode layer, anode layer and the active RFID assembly through the first substrate are performed by passing the generally continuous web through a printing station, and wherein the completed active RFID device on the generally continuous web is collected at a take-up station.

28. The method of claim 27, wherein said first substrate is provided on a source roll at said source station, and wherein said completed active RFID device is collected on a collection roll a said take-up station.