Device enclosures and devices with integrated battery

• US 20020004167A1
• Filed: 03/23/2001
• Published: 01/10/2002
• Est. Priority Date: 03/24/2000
• Status: Active Grant

• Current Assignee: Cymbet Corporation
• Original Assignee: Integrated Power Solutions, Inc.
• Inventors: Yan, Jenn-Feng, Klaassen, Jody Jon, Jenson, Mark Lynn, Weiss, Victor Henry
• Granted Patent: US 6,986,965 B2
• Time in Patent Office: Days
• 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. A case for an electrically powered device comprising:

a first enclosure portion;

a second enclosure portion, the first and the second enclosure portions adapted to enclose at least a portion of the electrically powered device; and

a thin-film battery manufactured as part of at least the first portion of the case.

2. The case of claim 1 wherein the battery is formed within the first portion of the case.

3. The case of claim 1 wherein the battery is sputtered onto the first portion of the case.

4. The case of claim 1 wherein the first portion and the second portion form an enclosure having an interior and an exterior surface, wherein the battery is formed having a contour substantially the same as the interior surface of the first portion of the case.

5. The case of claim 4 wherein the battery formed having a contour substantially the same as the interior surface of the first portion and is bonded to the interior surface of the first portion of the case.

6. The case of claim 5 further comprising a protective cover placed over the battery on the interior surface of the first portion of the case.

7. The case of claim 1 wherein the first portion and the second portion form an enclosure having an interior and an exterior surface, wherein the battery is formed having a contour substantially the same as the exterior surface of the first portion of the case.

8. The case of claim 7 wherein the battery formed having a contour substantially the same as the exterior surface of the first portion and is bonded to the exterior surface of the first portion of the case.

9. The case of claim 7 further comprising a protective cover placed over the battery on the exterior surface of the first portion of the case.

10. The case of claim 1 wherein the first portion and the second portion are hingedly attached to one another.

11. The case of claim 1 wherein the first portion and the second portion are attached by a living hinge.

12. The case of claim 1 wherein the battery is integrated within the first portion of the case, wherein the first portion further comprises:

an electrical trace; and

a site adapted to receive an electrically powered component, wherein the battery, the trace and the electrically powered component form at least a portion of a circuit.

13. An electrically powered device comprising:

a shell; and

a battery integrated with the shell.

14. The electrically powered device of claim 13 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.

15. The electrically powered device of claim 13 wherein the shell is a portion of an enclosure.

16. The electrically powered device of claim 13 wherein the battery is formed within the shell.

17. The electrically powered device of claim 16 wherein the battery is comprised of a plurality of layers.

18. The electrically powered device of claim 16 further comprising contacts associated with the battery, wherein the shell has an interior surface and an exterior surface, wherein the contacts are positioned near one of the interior surface or exterior surface.

19. The electrically powered device of claim 18 wherein there are a plurality of contacts associated with the battery, wherein the contacts can be configured to produce a plurality of different battery hook ups.

20. The electrically powered device of claim 13 wherein the battery is formed on the shell.

21. The electrically powered device of claim 20 wherein the shell has an interior surface and an exterior surface, wherein the battery is formed on one of the interior surface or exterior surface.

22. The electrically powered device of claim 20 further comprising a protective layer placed over the battery.

23. The electrically powered device of claim 20 wherein the shell has an interior surface and an exterior surface, wherein the battery is sputtered on one of the interior surface or exterior surface.

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

25. The electrically powered device of claim 20 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.

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

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

a trace on the interior surface of the shell; and

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

28. The electrically powered device of claim 13 further comprising a capacitor integrated within the shell.

29. The electrically powered device of claim 20 further comprising a capacitor on the shell.

30. A method for forming a shell comprising:

placing a battery on a sheet; and

forming the sheet into a desired shape.

31. The method of claim 30 wherein the desired shape is a portion of an enclosure for an electrical device.

32. The method of claim 30 wherein the desired shape includes a contoured surface corresponding to an enclosure for an electrical device.

33. The method of claim 32 wherein the desired shape includes a contoured surface corresponding to an interior surface of an enclosure for an electrical device.

34. The method of claim 32 wherein the desired shape includes a contoured surface corresponding to an exterior surface of an enclosure for an electrical device.

35. The method of claim 30 wherein the sheet is formed by vacuum forming.

36. The method of claim 30 further comprising adding electrical traces to the sheet.

37. The method of claim 30 further comprising adding electrical traces to the sheet before the forming step.

38. The method of claim 30 further comprising adding electrical traces to the sheet after the forming step.

39. The method of claim 30 further comprising adding electrical traces to the interior surface of the sheet, the electrical traces including a site for at least one electrically powered component.

40. A method for forming an electrical device comprising:

fabricating a plurality of battery cells on a sheet; and

forming the sheet into a desired shape.

41. The method for forming an electrical device of claim 40 further comprising folding the sheet to layer the plurality of battery cells.

42. The method of claim 40 further comprising placing electrical traces onto the sheet, the electrical traces for electrically coupling the plurality of battery cells.

43. The method of claim 40 further comprising placing electrical traces onto the sheet, the electrical traces for electrically coupling the plurality of battery cells, the electrical traces including a site adapted to receive an electrically powered component.

44. The method of claim 40 further comprising

cutting the sheet to include a desired number of battery cells;

and

folding the sheet after cutting to layer the plurality of battery cells.

45. The method of claim 40 further comprising

cutting the sheet to include a desired number of battery cells;

and

folding the sheet a plurality of times to layer the plurality of battery cells.

46. The method of claim 40, wherein the sheet is a substantially planar sheet during at least a portion of the fabricating function, and the desired shape is substantially non-planar.

47. The method of claim 46, further comprising assembling an electrically powered circuit to the sheet before the forming function.

48. The method of claim 46, further comprising assembling an electrically powered circuit to the sheet after the forming function.

49. The method of claim 46, further comprising assembling a motor to the sheet, wherein the motor is electrically coupled to the battery.

50. The method of claim 46, further comprising assembling a light source to the sheet, wherein the light source is electrically coupled to the battery.

51. A case for a manufactured electric-powered device comprising:

a first enclosure portion, the first enclosure portion shaped to be an outer surface of the device; and

a thin-film battery manufactured as part of the first enclosure portion of the case.

52. A method for recycling comprising:

determine if an electronic component associated with a portion of an electronic device enclosure is obsolete; and

separate the battery from the portion of the electronic device enclosure.

53. A method for recycling comprising:

determine if an electronic component associated with a portion of an electronic device enclosure is obsolete;

separate the obsolete component from the portion of the electronic device enclosure; and

replace the obsolete component.

54. 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 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.

55. The apparatus according to claim 54, wherein:

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

the electrolyte layer comprises LiPON.

56. The apparatus according to claim 54, wherein:

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

the electrolyte layer comprises LiPON.

57. The apparatus according to claim 54, wherein:

the electrolyte layer comprises LiPON; and

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

58. The apparatus according to claim 54, 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.