Device enclosures and devices with integrated battery

• US 6,986,965 B2
• Filed: 03/23/2001
• Issued: 01/17/2006
• Est. Priority Date: 03/24/2000
• Status: Expired due to Fees

• Current Assignee: Cymbet Corporation
• Original Assignee: Cymbet Corporation
• Inventors: Yan, Jenn-Feng, Klaassen, Jody Jon, Jenson, Mark Lynn, Weiss, Victor Henry
• Primary Examiner(s): Crepeau, Jonathan
• Application Number:
  US09/816,602
• Publication Number:
  US 20020004167A1
• Time in Patent Office: 1,761 Days
• Field of Search: 429/17, 429/24, 429/30, 429/122, 429/127, 429/162, 429/304, 429/306, 429/7, 429/9, 429/94, 429/124, 429/163, 429/176, 429/322, 438/484
• US Class Current: 429/162
• 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. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface; and

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell; and

a second shell enclosure portion, wherein the first shell and the second shell enclosure portions form a case adapted to enclose at least a portion of the electrically powered device, and wherein the first shell portion and the second shell portion are attached by a living hinge.

2. The device of claim 1, wherein at least a portion of the battery is sputtered on the first shell.

3. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface;

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell; and

a capacitor integrated within the first shell.

4. The device of claim 3, wherein at least a portion of the battery is sputtered on the first shell.

5. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface;

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell, wherein the battery is formed on the first shell; and

a capacitor formed on the first shell.

6. The device of claim 5, wherein at least a portion of the battery is sputtered on the first shell.

7. An integrated combined battery and device shell apparatus comprising:

an outer shell for an electronics device;

a first conductive layer deposited on a first surface area of the shell;

a second conductive layer deposited on a second surface area of the shell; and

a battery comprising a cathode layer;

an electrolyte layer, and an anode layer deposited such that the cathode layer is in electrical contact with the first conductive layer, the anode layer is in electrical contact with the second conductive layer, and the electrolyte layer is in contact with and completely separating the anode layer and the cathode layer, wherein the anode or the cathode or both include an intercalation material or a metal or both.

8. The apparatus according to claim 7, wherein:

the cathode layer comprises a lithium intercalation material deposited on the first conductive layer; and

the electrolyte layer comprises LiPON.

9. The apparatus according to claim 7, wherein:

the cathode layer comprises lithium cobalt oxide deposited on the first conductive layer; and

the electrolyte layer comprises LiPON.

10. The apparatus according to claim 7, wherein:

the electrolyte layer comprises LiPON; and

the anode layer comprises a lithium intercalation material deposited on the electrolyte layer.

11. The apparatus according to claim 7, wherein:

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

12. The device of claim 7, wherein at least a portion of the battery is sputtered on the outer shell.

13. The device of claim 7, wherein there is a plurality of contacts associated with the battery, wherein the contacts are configured to produce a plurality of different battery hook ups.

14. The apparatus of claim 7, wherein the battery includes thin-film layers that are successively deposited by sputtering on the first shell.

15. An electrically powered device comprising:

first enclosure portion means for enclosing the device, the first enclosure portion means shaped to form a convex outer surface case of the device; and

means for storing electrical energy manufactured as part of the first enclosure portion means of the case by successively depositing thin-film battery layers onto the first enclosure means, a surface of which forms the case'"'"'s outer surface, wherein the first enclosure portion means is rolled upon itself.

16. The device of claim 15, wherein the first enclosure portion means is rolled upon itself around an electrical motor, the device further comprising:

a shaft operatively coupled to the motor; and

a chuck placed upon the shaft to form a hand-held drill for homeowner use.

17. The device of claim 15, wherein the first enclosure portion means is rolled upon itself, the device further comprising:

an LED light electrically coupled to the battery to form a flashlight.

18. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface; and

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell,

wherein the first shell is rolled around an electrical motor, the device further comprising;

a shaft operatively coupled to the motor; and

a chuck placed upon the shaft to form a hand-held drill for homeowner use.

19. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface; and

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell,

wherein the first shell is rolled upon itself into a spiral, the device further comprising;

an LED light electrically coupled to the battery to form a flashlight.

20. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface; and

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell,

wherein the first shell forms at least a portion of an outer case for the electronics device, and further comprising;

a first conductive layer deposited on a first surface area of the first shell;

a second conductive layer deposited on a second surface area of the first shell; and

wherein the battery is comprised of a cathode layer;

an electrolyte layer, and an anode layer deposited such that the cathode layer is in electrical contact with the first conductive layer, the anode layer is in electrical contact with the second conductive layer, and the electrolyte layer in contact with and completely separating the anode layer and the cathode layer.

21. The electrically powered device of claim 20, wherein the battery is formed on the first shell.

22. The electrically powered device of claim 21, wherein the battery is formed on the interior surface.

23. The electrically powered device of claim 21 further comprising a protective layer placed over the battery.

24. The electrically powered device of claim 20, wherein the battery is sputtered on the interior surface.

25. The electrically powered device of claim 24 further comprising a protective layer placed over the battery.

26. The electrically powered device of claim 21 further comprising:

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.

27. The electrically powered device of claim 20, wherein the battery is formed on the exterior surface of the first shell, said first shell further comprising electrical contacts for the battery which are positioned near the interior surface of the first shell.

28. The electrically powered device of claim 27 further comprising:

a trace on the interior surface of the first shell; and

a site positioned on the interior surface of the first shell adapted to receive an electrically powered component, wherein the battery, the trace and the electrically powered component form a portion of a circuit.

29. The device of claim 20, wherein the cathode includes a metal.

30. The device of claim 20, wherein the cathode includes an intercalation material and a metal.

31. The device of claim 20, wherein the cathode includes a lithium intercalation material and lithium.

32. The device of claim 20, wherein the anode includes an intercalation material and the cathode includes an intercalation material.

33. The device of claim 20, wherein the first shell forms a plastic outer case for the electronics device, wherein the battery includes a cathode layer;

a lithium phosphorus oxynitride electrolyte layer, and an anode layer, and wherein the electrolyte layer is in contact with and completely separating the anode layer and the cathode layer, wherein the anode includes an intercalation material.

34. The device of claim 20, wherein the anode includes an intercalation material.

35. The device of claim 20, wherein the anode includes a metal.

36. The device of claim 20, wherein the anode includes an intercalation material and a metal.

37. The device of claim 20, wherein the anode includes a lithium intercalation material and lithium.

38. The electrically powered device of claim 21, wherein the battery is formed on the exterior surface.

39. The device of claim 20, wherein the cathode includes an intercalation material.

40. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface; and

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell, wherein the first shell forms at least one portion of a pacemaker enclosure, the pacemaker further including an energy-receiving device coupled to recharge the battery, and a heart-stimulation lead coupled to receive energy supplied by the battery.

41. The device of claim 40, wherein the energy-receiving device includes an antenna used to receive radio-frequency energy for recharging of the battery.

42. An electrically powered device comprising:

a first shell, wherein the first shell forms a portion of an enclosure for the device, the first shell having a concave interior surface and a convex exterior surface; and

a battery integrated with the first shell, wherein the battery is formed as one or more layers integral to the first shell, wherein the first shell has a shape having a convex surface opposite a concave surface, and is attached to an exterior surface of a watch, the watch further including a band attached to the enclosure and operative to strap onto a person'"'"'s wrist.

43. The device of claim 42, further comprising an energy-receiving device operatively coupled to recharge the battery.

44. The device of claim 42, further comprising a solar cell operatively coupled to recharge the battery, and an LCD within the enclosure.

45. An electrically powered device comprising:

first enclosure portion means for enclosing the device, the first enclosure portion means shaped to form a convex outer surface case of the device; and

means for storing electrical energy manufactured as part of the first enclosure portion means of the case by successively depositing thin-film layers for a battery onto the first enclosure means, a surface of which forms the case'"'"'s outer surface,

wherein the means for storing electrical energy comprise successive thin-film layers that are deposited on a surface that becomes a fan-folded zigzag in the device once finished.

46. An apparatus comprising:

a first shell for an electronics device;

a first conductive layer deposited on a first surface area of the first shell;

a second conductive layer deposited on a second surface area of the first shell; and

a thin-film lithium battery including a cathode layer;

an electrolyte layer, and an anode layer deposited such that the cathode layer is in electrical contact with the first conductive layer, the anode layer is in electrical contact with the second conductive layer, and the electrolyte layer is in contact with and completely separating the anode layer and the cathode layer.

47. The apparatus of claim 46, wherein:

the cathode layer comprises a lithium intercalation material deposited on the first conductive layer; and

the electrolyte layer comprises LiPON.

48. The apparatus of claim 46, wherein:

the cathode layer comprises lithium cobalt oxide deposited on the first conductive layer; and

the electrolyte layer comprises LiPON.

49. The apparatus of claim 46, wherein:

the electrolyte layer comprises LiPON; and

the anode layer comprises a lithium intercalation material deposited on the electrolyte layer.

50. The apparatus of claim 46, wherein:

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

51. The apparatus of claim 46, wherein the first shell is folded upon itself.

52. The apparatus of claim 46, wherein the first shell is rolled upon itself.

53. The apparatus of claim 46, wherein the first shell is rolled around an electrical motor, the device further comprising:

a shaft operatively coupled to the motor; and

a chuck placed upon the shaft to form a hand-held drill for homeowner use.

54. The apparatus of claim 46, wherein the first shell is rolled upon itself, the device further comprising:

an LED light electrically coupled to the battery to form a flashlight.

55. The apparatus of claim 46, wherein the cathode includes an intercalation material.

56. The apparatus of claim 46, wherein the cathode includes a metal.

57. The apparatus of claim 46, wherein the cathode includes an intercalation material and a metal.

58. The apparatus of claim 46, wherein the cathode includes a lithium intercalation material and lithium.

59. The apparatus of claim 46, wherein the anode includes an intercalation material and the cathode includes an intercalation material.

60. The device of claim 46, wherein the first shell forms at least one portion of a pacemaker enclosure, the pacemaker further including an energy-receiving device coupled to recharge the battery, and a heart-stimulation lead coupled to receive energy supplied by the battery.

61. The device of claim 46, wherein the energy-receiving device includes an antenna used to receive radio-frequency energy for recharging of the battery.

62. The device of claim 46, wherein the first shell has a shape having a convex surface opposite a concave surface, and is attached to an exterior surface of a watch, the watch further including a band attached to the enclosure and operative to strap onto a person'"'"'s wrist.

63. The device of claim 62, further comprising an energy-receiving device operatively coupled to recharge the battery.

64. The device of claim 62, further comprising a solar cell operatively coupled to recharge the battery, and an LCD within the enclosure.