Integrated electronic device and methods of making the same
First Claim
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1. A method of manufacturing an RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:
- providing a first substrate and a second substrate, at least one of which includes a plurality of layers, said first substrate including a first side and a second side;
providing an RFID assembly on said second side of said first substrate, including a RFID antenna, an RFID element in communication with the RFID antenna, and a plurality of electrical contacts in electrical communication with the RFID element;
printing or laminating a cathode layer on said first side of said first substrate;
printing or laminating an anode layer on said first side of said first substrate;
providing an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer;
electrically coupling the cathode layer, the anode layer, and the plurality of electrical contacts; and
connecting said second substrate to said first substrate to substantially seal an inner space containing said cathode layer, said anode layer, and said electrolyte layer,further comprising the step of providing a frame on said first side of said first substrate to form the inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space, andfurther including the step of providing the frame as a third substrate including a web having a plurality of laminated layers, wherein at least one of said laminated layers is a pressure-sensitive adhesive.
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Abstract
An integrated electronic device, and its method of manufacture, are provided. The integrated electronic device can include an electronic assembly, such as an active RFID assembly, that is electrically coupled to a thin printed flexible electrochemical cell. In one example, the electronic assembly and the electrochemical battery are provided on a single substrate. In one example method of manufacture, the entire cell to be made on a printing press to integrate the battery directly with the electronic assembly.
287 Citations
29 Claims
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1. A method of manufacturing an RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:
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providing a first substrate and a second substrate, at least one of which includes a plurality of layers, said first substrate including a first side and a second side; providing an RFID assembly on said second side of said first substrate, including a RFID antenna, an RFID element in communication with the RFID antenna, and a plurality of electrical contacts in electrical communication with the RFID element; printing or laminating a cathode layer on said first side of said first substrate; printing or laminating an anode layer on said first side of said first substrate; providing an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer; electrically coupling the cathode layer, the anode layer, and the plurality of electrical contacts; and connecting said second substrate to said first substrate to substantially seal an inner space containing said cathode layer, said anode layer, and said electrolyte layer, further comprising the step of providing a frame on said first side of said first substrate to form the inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space, and further including the step of providing the frame as a third substrate including a web having a plurality of laminated layers, wherein at least one of said laminated layers is a pressure-sensitive adhesive. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of manufacturing an RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:
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providing a first substrate and a second substrate, at least one of which includes a plurality of layers, said first substrate including a first side and a second side; providing an RFID assembly on said second side of said first substrate, including a RFID antenna, an RFID element in communication with the RFID antenna, and a plurality of electrical contacts in electrical communication with the RFID element; providing a cathode layer on said first side of said first substrate; providing an anode layer on said first side of said first substrate; providing an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer; electrically coupling the cathode layer, the anode layer, and the plurality of electrical contacts; and connecting said second substrate to said first substrate to substantially seal an inner space containing said cathode layer, said anode layer, and said electrolyte layer, further comprising the steps of providing a plurality of cathode layers and a plurality of anode layers, and electrically connecting said plurality of cathode layers and anode layers together to form a battery.
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12. A method of manufacturing an RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:
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providing a first substrate and a second substrate, at least one of which includes a web having a plurality of layers, said first substrate including a first side and a second side; providing an RFID assembly on said second side of said first substrate, including the steps of (i) providing an RFID element on said second side of said first substrate; and
(ii) printing an RFID antenna and a plurality of electrical contacts on said second side of said first substrate so as to be in electrical contact with said RFID element, wherein each of said RFID antenna and plurality of electrical contacts include a cured or dried ink;printing a cathode collector layer on said first side of said first substrate; printing a cathode layer on said first side of said first substrate; printing an anode layer on said first side of said first substrate; providing an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer; electrically coupling the cathode layer via the cathode collector, the anode layer, and the plurality of electrical contacts; and connecting said second substrate to said first substrate to substantially seal an inner space containing said cathode layer, said anode layer, and said electrolyte layer, wherein the step of electrically coupling the cathode layer, anode layer, and the plurality of electrical contacts further includes the steps of (1) providing a plurality of apertures extending through said first substrate so as to be in communication with each of the cathode layer, anode layer, and the plurality of electrical contacts; and
(2) filling each of said plurality of apertures with a conductive ink for providing said electrical communication between the cathode layer, anode layer, and the plurality of electrical contacts. - View Dependent Claims (13, 14, 15, 16)
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17. An RFID device including a flat electrochemical cell for generating an electrical current, said RFID device including:
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a first substrate including of a plurality of laminated layers and defining a first side and a second side; a second substrate; an RFID assembly provided on said second side of said first substrate, including a RFID antenna, an RFID element in communication with the RFID antenna, and a plurality of electrical contacts in electrical communication with the RFID element; a cathode layer provided on said first side of said first substrate; an anode layer provided on said first side of said first substrate; an electrolyte layer including a viscous liquid in contact with said cathode layer and also in contact with said anode layer, wherein at least one of said anode layer and said cathode layer include a cured or dried ink; and an electrical coupler assembly providing electrical communication between the cathode layer, the anode layer, and the plurality of electrical contacts, wherein said electrical coupler assembly includes a plurality of apertures extending through said first substrate, the plurality of apertures being in communication with each of the cathode layer, anode layer, and the plurality of electrical contacts, and wherein each of said plurality of apertures are filled with a conductive ink for providing said electrical communication between the cathode layer, anode layer, and the plurality of electrical contacts. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A method of manufacturing an RFID device including a flat electrochemical cell for generating an electrical current, said method including the steps of:
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providing a first substrate including a first side and a second side; providing an RFID assembly on said second side of said first substrate; providing a cathode collector layer on said first side of said first substrate; providing a cathode layer on said first side of said first substrate; providing an anode layer on said first side of said first substrate; providing an electrolyte layer in contact with said cathode layer and also in contact with said anode layer; and electrically coupling the cathode layer via the cathode collector layer, the anode layer, and the RFID assembly through the first substrate, further comprising the step of providing a frame on said first side of said first substrate to form an inner space containing said electrolyte, and also containing at least a major portion of said cathode layer and at least a major portion of said anode layer within said inner space. - View Dependent Claims (28, 29)
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Specification