CONFORMAL SOLID STATE PACKAGE METHOD AND DEVICE FOR A BATTERY DEVICE

• US 20120135292A1
• Filed: 01/23/2012
• Published: 05/31/2012
• Est. Priority Date: 10/31/2011
• Status: Abandoned Application

• Current Assignee: Sakti3, Inc
• Original Assignee: Sakti3, Inc
• Inventors: Buckingham, Stephen, Sastry, Ann Marie, Langlois, Marc, Lukich, Svetlana
• Application Number:
  US13/356,570
• Publication Number:
  US 20120135292A1
• Time in Patent Office: Days
• US Class Current: 429/153
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/131 characterised by physical properties, e.g. gas permeability, size or heat resistance
• CPC Class Codes: H01M 50/133 Thickness
• CPC Class Codes: H01M 50/14 for protecting against damage caused by external factors
• 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

Abstract

A monolithically integrated thin-film solid-state lithium battery device to supply energy to a mobile communication device. The device includes a plurality of layers ranging from greater than 100 layers to less than 20,000 layers of lithium electrochemical cells, which may be connected in parallel or in series to conform to a spatial volume. The device also includes a polymer based coating characterized by a thickness to house the plurality of layers and configured as an exterior region for the battery device, the polymer based coating having a resistivity of 10¹² Ω.cm and higher. The device further includes a hermetic seal provided by the polymer-based coating to enclose and house the plurality of layers.

Claims

1. A monolithically integrated thin-film solid-state lithium battery device to supply energy to a mobile communication device, the battery device comprising:

a plurality of layers ranging from greater than 100 layers to less than 20,000 layers of lithium electrochemical cells, the lithium electrochemical cells being connected in parallel or in series to conform to a spatial volume;

a polymer based coating characterized by a thickness to house the plurality of layers and configured as an exterior region for the battery device, the polymer based coating having a resistivity of 10¹² Ω

.cm and higher; and

a hermetic seal provided by the polymer based coating to enclose and house the plurality of layers.

2. The device of claim 1 further comprising a diffusion coefficient of 10⁻

6 cm²/sec and less characterizing the polymer based coating.

3. The device of claim 1 further comprising water vapor transmission rate to <

10<sup>−

4</sup> gm/m²/day.

4. The device of claim 1 wherein the polymer based coating is selected from epoxy, polyurethane, thermoplastics, acrylate ceramics, liquid crystals, phenol formaldehyde, butadiene or acrylonitrile, phthalic acid, polyvinylidene chloride, silicon, polytetrafluoroethylene, silica, graphite, carbon black, MgO, SiO₂, SiC, TiC, Al₂O₃, PMMA or combinations.

5. The device of claim 1 wherein the polymer based coating having a sufficient rigidity and thickness to enclose the plurality of layers and provide mechanical protection to the plurality of layers.

6. The device of claim 1 further comprising a substrate and the overlying multiple layers;

wherein the overlying multiple layers are free from any intermediary substrate member;

wherein the multiple layers are configured to form a plurality of electrochemical cells configured in a parallel arrangement or a serial arrangement using either a self terminated or post terminated connector configuration.

7. The device of claim 1 further comprising an energy density of 500 Watt-hours/liter and greater.

8. The device of claim 1 wherein the spatial volume is 1 liter and less;

wherein the polymer based coating comprises a desiccant material, wherein the polymer based material comprises a moisture barrier;

wherein the polymer based material comprises a static discharge material;

wherein the polymer material comprises a plurality of gettering materials.

9. The device of claim 1 wherein the polymer based material comprises multi layers including barrier, getter, adhesion, modulus modifying, stress modifying, electrical conductivity modifying, color modifying, surface energy modifying.

10. The device of claim 1 wherein the polymer based material has a conformal characteristic and is playable.

11. A method for fabricating a monolithically integrated thin-film solid-state lithium battery device to supply energy to a mobile communication device, the method comprising:

providing a plurality of layers ranging from greater than 100 layers to less than 20,000 layers of lithium electrochemical cells, the lithium electrochemical cells being connected in parallel or in series to conform to a spatial volume;

forming a polymer based coating characterized by a thickness to house the plurality of layers and configured as an exterior region for the battery device, the polymer based coating having a resistivity of 10¹² Ω

.cm and higher; and

whereupon the polymer based coating characterized by a hermetic seal provided by the polymer based coating to enclose and house the plurality of layers.

12. The method of claim 11 further comprising a diffusion coefficient of 10⁻

6 cm²/sec and less characterizing the polymer based coating.

13. The method of claim 11 further comprising a water vapor transmission rate to <

10<sup>−

4</sup> gm/m²/day;

wherein the polymer based material has a conformal characteristic and is pliable.

14. The method of claim 11 wherein the polymer based coating is selected from epoxy, polyurethane, thermoplastics, acrylate ceramics, liquid crystals, phenol formaldehyde, butadiene or acrylonitrile, phthalic acid, polyvinylidene chloride, silicon, polytetrafluoroethylene, silica, graphite, carbon black, MgO, SiO₂, SiC, TiC, Al₂O₃, PMMA or combinations.

15. The method of claim 11 wherein the polymer based coating having a sufficient rigidity and thickness to enclose the plurality of layers and provide mechanical protection to the plurality of layers.

16. The method of claim 11 further comprising a substrate and the overlying multiple layers;

wherein the overlying multiple layers are free from any intermediary substrate member;

wherein the multiple layers are configured to form a plurality of electrochemical cells configured in a parallel arrangement or a serial arrangement using either a self terminated or post terminated connector configuration.

17. The method of claim 11 further comprising an energy density of 500 Watt-hours/liter and greater.

18. The method of claim 11 wherein the spatial volume is 1 liters and less;

wherein the polymer based coating comprises a desiccant material;

wherein the polymer based coating comprises a moisture barrier;

wherein the polymer based material comprises a static discharge material;

wherein the polymer based material comprises a plurality of gettering materials.

19. The method of claim 11 wherein the polymer based material comprises multi layers including barrier, getter, adhesion, modulus modifying, stress modifying, electrical conductivity modifying, color modifying, surface energy modifying.

20. The method of claim 11 wherein the forming of the polymer based coating comprises dipping, spraying, or electrostatic spraying, flame spraying, arc spraying, laser spraying, atmospheric plasma polymerization, vacuum plasma polymerization, sub atmosphere condensation, spin coating, and atmospheric condensation, ultrasonic ammonization, modified atmosphere coating (Argon, etc), modified nano-spraying (fumed silica, etc.), and combinations thereof.