Card with embedded IC and electrochemical cell

• US 6,936,377 B2
• Filed: 05/13/2003
• Issued: 08/30/2005
• Est. Priority Date: 05/13/2003
• Status: Expired due to Term

• Current Assignee: Brightvolt, Inc.
• Original Assignee: Solicore Incorporated
• Inventors: Wensley, C. Glen, Nelson, Craig R., Gustafson, Scott
• Primary Examiner(s): Maples, John S.
• Application Number:
  US10/437,546
• Publication Number:
  US 20040229118A1
• Time in Patent Office: 840 Days
• Field of Search: 429/162, 429/122, 429/306, 235/380, 235/492, 257/679, 257/924
• US Class Current: 429/162
• CPC Class Codes: H01M 10/044 with bipolar electrodes
• 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 10/0565 Polymeric materials, e.g. gel-type or solid-type
• 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 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 2300/0091 in the form of mixtures
• CPC Class Codes: H01M 50/11 having a chip structure, e.g. micro-sized batteries integrated on chips
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/198 characterised by physical properties, e.g. adhesiveness or hardness
• CPC Class Codes: H01M 50/446 Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: H01M 6/181 with polymeric electrolytes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• 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: Y10S 257/924 with passive device, e.g. capacitor, or battery, as integral part of housing or housing element, e.g. cap
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49112 : including laminating of indefinite length material

Abstract

An IC card includes at least one plastic layer, a battery and at least one electronic device embedded in the plastic layer. The battery is electrically connected to the electronic device for providing power to the device. The battery includes an anode, a cathode, and at least one polymer matrix electrolyte (PME) separator disposed between the anode and the cathode. The PME separator includes a polyimide, at least one lithium salt and at least one solvent all intermixed. The PME is substantially optically clear and stable against high temperature and pressure, such as processing conditions typically used in hot lamination processing or injection molding.

Claims

1. An IC card, comprising:

at least one plastic layer;

a battery and at least one electronic comprising device embedded in said plastic layer, said battery electrically connected to said electronic comprising device for providing power for said electronic comprising device;

said battery comprising;

an anode;

a cathode, and

at least one polymer matrix electrolyte (PME) separator disposed between said anode and said cathode, said PME separator comprising a polyimide, at least one lithium salt and at least one solvent intermixed, said PME being substantially optically clear.

2. The IC card of claim 1, wherein said anode comprises lithium ion intercalation material.

3. The IC card of claim 1, wherein said anode comprises lithium metal.

4. The IC card of claim 1, wherein said anode comprises a lithium metal alloy anode.

5. The IC card of claim 1, wherein a repeat unit weight per imide ring of said polyimide is no more than 350.

6. The IC card of claim 1, wherein a repeat unit weight per imide ring of said polyimide is no more than 300.

7. The IC card of claim 1, wherein a repeat unit weight per imide ring of said polyimide is no more than 250.

8. The IC card of claim 1, wherein said polyimide is soluble at 25°

C. in at least one solvent selected from the group consisting of N-methylpyrrolidinone (NMP), dimethylacetamide (DMAc) and dimethylformamide (DMF).

9. The IC card of claim 1, wherein the ionic conductivity of said PME at 25°

C. is at least 1×

10<sup>−

4</sup> S/cm.

10. The IC card of claim 1, wherein the ionic conductivity of said PME at 25°

C. is at least 3×

10<sup>−

4</sup> S/cm.

11. The IC card of claim 1, wherein said Li salt is at least one selected from the group consisting of LiCl, LiBr, Lil, LiClO₄, LiBF₄, LiAsF₆, LiPF₆, LiCF₃SO₃, LiBOB, LiN(CF₃SO₂)₂, and lithium bis(trifluorosulfonyl)imide (LiTFSI).

12. The IC card of claim 1, wherein said cathode comprises an ion conducting polymeric binder intermixed with an intercalation material.

13. The IC card of claim 12, wherein said polymeric binder comprises at least one polyimide.

14. The IC card of claim 1, wherein said battery provides an open circuit voltage and capacity shift of less than 10% following heating at 125°

C. for at least 5 minutes while under a pressure of at least 250 psi.

15. The IC card of claim 1, wherein said battery provides an open circuit voltage and capacity shift of less than 5% following heating at 125°

C. for at least 5 minutes while under a pressure of at least 250 psi.

16. The IC card of claim 1, wherein said battery is a primary battery.

17. The IC card of claim 1, wherein said battery is a secondary battery.

18. The IC card of claim 1, wherein said battery is a bicell.

19. The IC card of claim 1, wherein said lithium salt is in a concentration of at least 0.5 moles of lithium per mole of imide ring provided by said polyimide.

20. The IC card of claim 1, further comprising a package comprising packaging material surrounding said battery to form a packaged battery, said packaging material laminated by an exterior binder adhesive to all exterior surfaces of said battery.

21. The IC card of claim 1, further comprising a package including packaging material surrounding said battery and a frame having an opening to accommodate said battery therein to form a packaged battery, wherein said battery is disposed within said opening.

22. The IC card of claim 21, wherein said packaged battery provides a thickness uniformity throughout within ±

1 mil.

23. The IC card of claim 22, further comprising an exterior binder adhesive disposed between said packaged battery and said plastic layer to bind said packaged battery to said plastic layer, wherein said exterior binder adhesive is activated at a temperature of at least 100 C.

24. The IC card of claim 23, wherein an interior binder adhesive seals said battery, wherein said interior binder adhesive has an activation temperature which is lower than an activation temperature of said exterior binder adhesive.

25. The IC card of claim 24, wherein said IC card provides a thickness uniformity throughout within ±

1 mil.

26. The IC card of claim 1, wherein said IC card complies with ISO testing criteria for bending, flex, and torsion according to ISO standards ISO/IEC 10373 and 14443 without inducing any visually detectable delamination.