Integrated thin film battery and circuit module

• US 7,045,246 B2
• Filed: 04/22/2003
• Issued: 05/16/2006
• Est. Priority Date: 04/22/2003
• Status: Expired due to Fees

• Current Assignee: Aerospace Corporation, Nexolve Holding Company, LLC
• Original Assignee: Aerospace Corporation, SRS Technologies, Inc. (Mantech International Corporation)
• Inventors: Simburger, Edward J., Gierow, Paul A., Matsumoto, James H., Hepp, Aloysius F.
• Primary Examiner(s): Ruthkosky, Mark
• Application Number:
  US10/420,463
• Publication Number:
  US 20040214079A1
• Time in Patent Office: 1,120 Days
• Field of Search: 429/122, 429/124
• US Class Current: 429/124
• 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 6/12 with flat electrodes
• 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: H05K 1/16 incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• CPC Class Codes: H05K 2201/0317 Thin film conductor layer; Thin film passive component
• CPC Class Codes: H05K 2201/10037 Printed or non-printed battery
• CPC Class Codes: H05K 3/429 Plated through-holes specially for multilayer circuits, e.g. having connections to inner circuit layers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

One or more thin film battery cells are embedded in a multilayer thin film flexible circuit board supporting electronic devices, such as power regulators, for forming an integrated battery and circuit module. The module can be made using conventional thin film processes. The module is well suited for applications where size and space limitations, such as on spacecraft or credit cards, require the use of ultra thin power sources integrated with respective electronic devices and printed circuits.

Claims

1. A battery module for routing power, the module is a thin film module made from thin film processes, the module comprising,

a first circuit layer comprising a first plurality of insulating polymer layers,

conductor traces horizontally disposed between and on the first plurality of circuit layers,

a thin film battery disposed on the first circuit layer,

feedthrough traces vertically disposed through the plurality of circuit layers, and

a first electronic device, the conductor traces and feedthrough traces serving to interconnect the first electronic device to the thin film battery.

2. The module of claim 1 wherein,

the conductor traces are made of copper.

3. The module of claim 1 wherein,

the feedthrough traces are made of copper.

4. The module of claim 1 wherein the thin film battery comprises,

an anode collector,

an anode,

an electrolyte,

a cathode, and

a cathode collector.

5. The module of claim 1 wherein the thin film battery comprises,

a plurality of thin film battery cells, each of the thin film battery cells comprises an anode collector, an anode, an electrolyte, a cathode, and a cathode collector.

6. The module of claim 1, wherein

a first one of feedthrough traces is a positive terminal of the thin film battery, and

a second one of the feedthrough traces is a negative terminal of the thin film battery.

7. The module of claim 1 further comprising,

a second circuit layer comprising a second plurality of insulating polymer layers, the conducting traces further extending between and on the second plurality of insulating polymer layers, the feedthrough traces further extending vertically through the second circuit layer.

8. The module of claim 1 further comprising,

a second circuit layer comprising a second plurality of insulating polymer layers, the conducting traces further extending between and on the second plurality of insulating polymer layers, the feedthrough traces further extending vertically through the second circuit layer, and

a second electronic device disposed on the second circuit layer, the conductor traces and feedthrough traces serving to interconnect the first and second electronic devices to the thin film battery.

9. The module of claim 1 wherein the thin film battery comprises,

a thin film cathode collector disposed as a thin film layer on the first circuit layer opposite the first electronic device,

a thin film cathode disposed as a thin film layer on the thin film cathode collector,

a thin film electrolyte disposed as a thin film layer on the thin film cathode,

a thin film anode disposed as a layer on the electrolyte, and

a thin film anode collector disposed as a layer on the thin film anode.

10. The module of claim 1 wherein the first circuit layer is made of polyimide.

11. The module of claim 1 wherein the first electronic devices is a power regulator.

13. The module of claim 1 wherein,

the first and second conductor traces and the feedthrough traces are made of copper.

14. The module of claim 1 wherein,

the first and second conductor traces and the feedthrough traces are made of copper,

the first and second conductor traces are made by patterned deposition, and

the feedthrough traces are formed by drilled holes in which copper is deposited.

12. A battery module for routing power, the module is a thin film module made from thin film processes, the module comprising,

a first circuit layer comprising a first plurality of insulating polymer layers,

first conductor traces horizontally disposed between and on the first plurality of circuit layers,

a thin film battery cell disposed on the first circuit layer, the thin film battery comprising a thin film cathode collector disposed as a thin film layer on the first circuit layer opposite the first electronic device, comprising a thin film cathode disposed as a thin film layer on the thin film cathode collector, comprising a thin film electrolyte disposed as a thin film layer on the thin film cathode, comprising a thin film anode disposed as a layer on the electrolyte, and comprising a thin film anode collector disposed as a layer on the thin film anode,

feedthrough traces vertically disposed through the first and second circuit layers, and

a first electronic device disposed on the first circuit layer opposite the thin film battery cell,

a second circuit layer disposed on the thin film battery cell and comprising a second plurality of insulating polymer layers,

second conductor traces horizontally disposed between and on the first plurality of circuit layers,

a second electronic device disposed on the second circuit layer opposite the thin film battery cell, the first and second conductor traces and feedthrough traces serving to interconnect the first and second electronic devices to the thin film battery cell.