U.S. patent application number 14/041575 was filed with the patent office on 2014-01-30 for thin film battery on an integrated circuit or circuit board and method thereof.
This patent application is currently assigned to Infinite Power Solutions, Inc.. The applicant listed for this patent is Timothy J. Bradow, Paul C. Brantner, Raymond R. Johnson, Bernd J. Neudecker, Shawn W. Snyder. Invention is credited to Timothy J. Bradow, Paul C. Brantner, Raymond R. Johnson, Bernd J. Neudecker, Shawn W. Snyder.
Application Number | 20140030584 14/041575 |
Document ID | / |
Family ID | 38685525 |
Filed Date | 2014-01-30 |
United States Patent
Application |
20140030584 |
Kind Code |
A1 |
Johnson; Raymond R. ; et
al. |
January 30, 2014 |
THIN FILM BATTERY ON AN INTEGRATED CIRCUIT OR CIRCUIT BOARD AND
METHOD THEREOF
Abstract
An electrochemical device includes an environmentally sensitive
layer and a thin encapsulation layer deposited over said sensitive
layer in which the thin encapsulation is a ceramic-metal composite
laminate.
Inventors: |
Johnson; Raymond R.;
(Denver, CO) ; Snyder; Shawn W.; (Golden, CO)
; Brantner; Paul C.; (Conifer, CO) ; Bradow;
Timothy J.; (Littleton, CO) ; Neudecker; Bernd
J.; (Littleton, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson; Raymond R.
Snyder; Shawn W.
Brantner; Paul C.
Bradow; Timothy J.
Neudecker; Bernd J. |
Denver
Golden
Conifer
Littleton
Littleton |
CO
CO
CO
CO
CO |
US
US
US
US
US |
|
|
Assignee: |
Infinite Power Solutions,
Inc.
Littleton
CO
|
Family ID: |
38685525 |
Appl. No.: |
14/041575 |
Filed: |
September 30, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11748471 |
May 14, 2007 |
|
|
|
14041575 |
|
|
|
|
Current U.S.
Class: |
429/163 ;
429/188; 429/209 |
Current CPC
Class: |
H01M 10/052 20130101;
Y10T 29/49114 20150115; H01M 10/0562 20130101; H01L 2924/0002
20130101; H01M 10/0585 20130101; H01L 23/58 20130101; H01M 2/08
20130101; H01M 6/40 20130101; H01M 2/26 20130101; H01M 10/0525
20130101; H01M 2/0207 20130101; Y10T 29/4911 20150115; H01M 2220/30
20130101; Y02E 60/10 20130101; H01M 10/425 20130101; H01M 2300/0068
20130101; H01M 10/0436 20130101; Y02P 70/50 20151101; H01L
2924/0002 20130101; H01L 2924/00 20130101 |
Class at
Publication: |
429/163 ;
429/209; 429/188 |
International
Class: |
H01M 2/08 20060101
H01M002/08 |
Claims
1. An electrochemical device comprising: an environmentally
sensitive layer; and a thin encapsulation layer deposited over said
sensitive layer, comprising a ceramic-metal composite laminate.
2. The electrochemical device of claim 1, wherein said
ceramic-metal composite laminate include metallic sub-layers that
comprise at least one element selected from the group comprising:
zirconium and titanium.
3. The electrochemical device of claim 1, wherein said
ceramic-metal composite laminate includes ceramic sub-layers
comprising nitrides.
4. The electrochemical device of claim 1, wherein said
environmentally sensitive layer is lithium.
5. The electrochemical device of claim 1, wherein said electrolyte
comprises LIPON.
6. The electrochemical device of claim 1, wherein said
electrochemical device is positioned on a flexible circuit
board.
7. The electrochemical device of claim 1, further comprising a
modulating layer between the encapsulant and the environmentally
sensitive material.
8. An electrochemical device comprising: a cathode; an anode; an
electrolyte; and a thin encapsulation layer at the periphery of
said device, comprising a ceramic-metal composite laminate.
9. The electrochemical device of claim 8, wherein said a
ceramic-metal composite laminate includes metallic sub-layers
comprise at least one element selected from the group comprising:
zirconium and titanium.
10. The electrochemical device of claim 8, wherein said a
ceramic-metal composite laminate includes ceramic sub-layers
comprising nitrides.
11. The electrochemical device of claim 8, wherein said anode is
lithium.
12. The electrochemical device of claim 8, wherein said electrolyte
is LIPON anode.
13. The electrochemical device of claim 8, wherein said cathode is
LiCo0.sub.2.
14. The electrochemical device of claim 8, wherein said
electrochemical device is positioned on a flexible circuit
board.
15. The electrochemical device of claim 8, further comprising a
modulating layer between the encapsulant and the anode.
16. An electrochemical device comprising: an environmentally
sensitive layer; and a thin encapsulation layer deposited over said
sensitive layer, comprising a plurality of alternating metallic
sublayers and ceramic sub-layers.
17. The electrochemical device of claim 16, wherein said metallic
sub-layers comprise at least one element selected from the group
comprising: zirconium and titanium.
18. The electrochemical device of claim 16, wherein said ceramic
sub-layers comprising nitrides.
19. The electrochemical device of claim 16, wherein said
environmentally sensitive layer is lithium.
20. The electrochemical device of claim 16, further comprising a
modulating layer between the encapsulant and the environmentally
sensitive material.
Description
[0001] The present invention is a continuation, and claims benefit
under 35 U.S.C. .sctn.120, of U.S. patent application Ser. No.
11/748,471, filed on 14 May 2007, which is incorporated herein in
its entirety by reference; and which is a continuation in part, and
claims benefit under 35 U.S.C. .sctn.120, of U.S. patent
application Ser. No. 11/687,032, entitled Metal Film Encapsulation,
filed 16 Mar. 2007, which claims benefit under 35 U.S.C. .sctn.119
of U.S. provisional patent application Ser. No. 60/782,792, filed
16 Mar. 2006, and of U.S. provisional patent application Ser. No.
60/799,904, filed on May 12, 2006, all of which are incorporated
herein in their entirety by reference. The present application also
relates to U.S. provisional patent application Ser. No. 11/561,277,
entitled Hybrid Thin Film Battery, filed 17 Nov. 2006, which claims
benefit under 35 U.S.C. .sctn.119 of U.S. provisional patent
application Ser. No., 60/759,479, filed 17 Jan. 2006, and which is
incorporated herein in its entirety by reference. The present
application also relates to U.S. provisional patent application
Ser. No. 60/737,613, entitled Flexible, Rechargeable, Solid-State,
Ultra-Thin Performance Battery, filed 17 Nov. 2005, which is
incorporated herein in its entirety by reference. The present
application also relates to U.S. patent application Ser. No.
11/209,536, entitled Electrochemical Apparatus with Barrier Layer
Protected Substrate, filed 23 Aug. 2005, which is incorporated
herein in its entirety by reference. The present application also
relates to U.S. patent application Ser. No. 11/374,282, entitled
Electrochemical Apparatus with Barrier Layer Protected Substrate,
filed Jun. 15, 2005, which is incorporated herein in its entirety
by reference. The present application also relates to U.S. Pat. No.
6,916,679, entitled Methods of and Device for Encapsulation and
Termination of Electronic Devices, issued 12 Jul. 2005, which is
incorporated herein in its entirety by reference. The present
application also relates to U.S. provisional patent application
Ser. No. 60/690,697, entitled Electrochemical Apparatus with
Barrier Layer Protected Substrate, filed 15 Jun. 2005, which is
incorporated herein in its entirety by reference. The present
application also relates to U.S. patent application Ser. No.
10/611,431, entitled Method and Apparatus for an Ambient Energy
Battery or Capacitor Recharge System, filed 2 Jul. 2003, which
further claims the benefit of U.S. provisional patent application
Ser. No. 60/464,357, filed 22 Apr. 2003, each of which are
incorporated herein in their entirety by reference.
FIELD OF THE INVENTION
[0002] The field of this invention is the device, composition,
method of depositing and fabrication of flexible solid-state,
thin-film, secondary and primary electrochemical devices, including
batteries, onto a semiconducting surface, onto a conductive or
insulating surface of a semiconductor device, such as integrated
circuit chips, or onto a circuit board, such as printed circuit
board.
BACKGROUND
[0003] Typical electrochemical devices comprise multiple
electrically active layers such as an anode, cathode, electrolyte,
substrate, current collectors, etc. Some layers, such as, for
example, an anode layer comprising lithium, are comprised of
materials that are very environmentally sensitive. The substrate
may, for example, not be a separate battery element but instead be
provided by a semiconducting surface or onto a conductive or
insulating packaging surface of a semiconductor device to which the
battery is attached. Such batteries require an encapsulation to
protect such environmentally sensitive material. Some schemes
encapsulate the sensitive layers of electrochemical devices, such
as encapsulation with gold foil. Other schemes encapsulate the
device with pouch, for example, made of metal and plastic, that
seals around the perimeter of the device.
SUMMARY
[0004] An exemplary embodiment of the present invention includes a
battery fabricated on a semiconductor chip or fabricated on a
flexible printed circuit board. The battery may, for example,
include a first electrical contact, a bonding layer coupled with
the first electrical contact and having a first embedded conductor,
at least one battery cell structure in selective electrical contact
with said first electrical contact via the first embedded
conductor, a semiconducting surface or a conductive or insulating
packaging surface of a semiconductor device.
[0005] The bonding layer coupled with the semiconducting surface or
a conductive or insulating packaging surface of a semiconductor
device may have more than one conductor, such an optional, second
embedded conductor, which in turn creates an optional, selective
electrical contact of the semiconducting surface or a conductive or
insulating packaging surface of a semiconductor device with said
first electrical contact. In any case, the bonding layer and the at
least one battery cell structure may be sandwiched between the
first contact layer and the semiconducting surface or the
conductive or insulating packaging surface of a semiconductor
device.
[0006] The first electrical contact may, for example, include an
encapsulate metal. The bonding layer may be an adhesive material,
an insulating material, a plastic, a polymeric material, glass,
and/or fiberglass. An insulative reinforcement layer may be
embedded within the bonding layer. Such a reinforcement layer may
be selectively conductive. The conductor may be, for example, a
tab, a wire, a metal strip, a metal ribbon, multiple wires,
multiple metal strips, multiple metal ribbons, a wire mesh,
perforated metal, a metal coating applied to the adhesive layer, or
a disk. The conductor may be woven within the bonding layer and the
bonding layer may include a slit within which the embedded
conductor is woven.
[0007] The battery cell structure may include an anode, an
electrolyte, a cathode, and a barrier layer. The cathode may, for
example, not be annealed at all, annealed at lower temperatures, or
annealed at higher temperatures, by using convection furnaces,
rapid thermal anneal methods, or by a laser annealing and/or
crystallization process.
[0008] Another exemplary embodiment of the present invention
includes a method of manufacturing a thin film battery comprising,
in no particular order, the steps of creating a selectively
conductive bonding layer, coupling the bonding layer with a first
contact layer, coupling a first side of a battery cell structure
with a semiconducting surface or a conductive or insulating surface
of a semiconductor device or flexible printed circuit board, and
coupling a second side of the battery cell structure with the
bonding layer. Optionally, the bonding layer may be made
selectively conductive at an additional location at which the
selectively conductive boding layer creates an electrical contact
between the first contact layer and the semiconducting surface or a
conductive or insulating surface of a semiconductor device or
flexible printed circuit board. Yet another exemplary embodiment of
the present invention includes a method of manufacturing a thin
film battery comprising, in no particular order, the steps of
creating a selectively conductive bonding layer, coupling the
bonding layer with a first contact layer, coupling a first side of
a battery cell with the first contact layer as well, coupling the
bonding layer with the a semiconducting surface or a conductive or
insulating surface of a semiconductor device or flexible printed
circuit board, and coupling a second side of the battery cell
structure with the bonding layer.
[0009] Examples of this embodiment may include creating a battery
cell structure with an anode, cathode, and electrolyte layers,
embedding at least one conductor within the bonding layer, weaving
at least one conductive wire through the bonding layer wherein
selective portions of the conductive wire are exposed, heating the
bonding layer and compressing the conductor within the bonding
layer, and insulating the battery with an insulating material. This
exemplary embodiment may include providing an insulative
reinforcement layer embedded within the bonding layer. The
reinforcement layer may be selectively conductive.
[0010] Yet another exemplary embodiment of the present invention
involves a battery on a flexible printed circuit board wherein the
first side of the battery cell structure is at least in direct
mechanical contact with the flexible printed circuit board. The
battery includes a first electrical contact, a bonding layer
coupled with the first electrical contact and comprising an first
embedded conductor, at least one battery cell structure in
selective electrical contact with the first electrical contact via
the first embedded conductor, the bonding layer coupled with the
first electrical contact and comprising a second embedded conductor
that is in selective electrical contact with the first electrical
contact and the flexible printed circuit board. The bonding layer
and the at least one battery cell structure are sandwiched between
the first contact layer and a flexible printed circuit board.
[0011] Another exemplary embodiment of the present invention
involves a battery on a flexible printed circuit board wherein the
battery cell structure is not in direct mechanical contact with the
flexible printed circuit board but mechanically separated by at
least the bonding layer. The battery includes a first electrical
contact, a bonding layer coupled with the first electrical contact
and comprising a first embedded conductor, at least one battery
cell structure in selective electrical contact with the first
electrical contact via said first embedded conductor, the bonding
layer coupled with the flexible printed circuit board and having an
optional, second embedded conductor in the bonding layer, which in
turn creates an optional, selective electrical contact of the
flexible printed circuit board with said first electrical contact.
The bonding layer and the at least one battery cell structure are
sandwiched between the first contact layer and a flexible printed
circuit board.
[0012] In another exemplary embodiment, a method of manufacturing a
thin film battery includes creating a selectively conductive
bonding layer, coupling the bonding layer with a first contact
layer, coupling a first side of a battery cell structure with a
flexible printed circuit board; and coupling a second side of the
battery cell structure with the bonding layer.
[0013] In yet another exemplary embodiment, a method of
manufacturing a thin film battery includes creating a selectively
conductive bonding layer, coupling the bonding layer with a first
contact layer, coupling a first side of a battery cell structure
with the first contact layer; and coupling a second side of the
battery cell structure with the selectively conductive bonding
layer, and coupling the bonding layer with the flexible printed
circuit board.
[0014] Another exemplary embodiment of the present invention
includes the electrical connection between the battery cell and the
semiconducting surface or the conductive packaging surface of a
semiconductor device. The electrical connection between the battery
cell and the semiconducting surface or the conductive packaging
surface of a semiconductor device can be made by direct physical
contact or by wire bonding.
[0015] In another aspect, prior to its integration onto the
semiconducting surface or a conductive or insulating packaging
surface of a semiconductor device or into or onto a flexible
printed circuit board, the battery may be fabricated as a discrete
device and then integrated as a whole together with its substrate
and its encapsulation.
[0016] Another embodiment of the present invention includes the
electrical connection between a multi-battery cell stack and the
semiconducting surface or the conductive packaging surface of a
semiconductor device.
BRIEF DESCRIPTION OF THE FIGURES
[0017] FIG. 1A shows a side view of an example of a thin film
battery with a semiconducting surface or the conductive or
insulating surface of a semiconductor device or a flexible printed
circuit board according to an exemplary embodiment of the present
invention.
[0018] FIG. 1B shows a side view of another example of a thin film
battery with a semiconducting surface or the conductive or
insulating packaging surface of a semiconductor device or a
flexible printed circuit board according to an exemplary embodiment
of the present invention.
[0019] FIG. 2 shows a side view of an example of a thin film
battery with a semiconducting surface or the conductive or
insulating surface of a semiconductor device according to another
exemplary embodiment of the present invention.
[0020] FIG. 3A shows a side view of an exemplary thin film battery
on a semiconducting surface or the conductive or insulating
packaging surface of a semiconductor device or a flexible printed
circuit board according to another exemplary embodiment of the
present invention.
[0021] FIG. 3B shows a side view of an exemplary thin film battery
on a semiconducting surface or the conductive or insulating surface
of a semiconductor device or flexible printed circuit board
according to another exemplary embodiment of the present
invention.
[0022] FIG. 3C shows a top view of an exemplary thin film battery
on a semiconducting surface or the conductive or insulating surface
of a semiconductor device or flexible printed circuit board
according to another exemplary embodiment of the present
invention.
[0023] FIG. 4A shows a side view of an exemplary thin film battery
on a semiconducting surface or the conductive or insulating surface
of a semiconductor device according to another exemplary embodiment
of the present invention.
[0024] FIG. 4B shows a side view of an exemplary thin film battery
on a flexible printed circuit board according to another exemplary
embodiment of the present invention.
DETAILED DESCRIPTION
[0025] FIG. 1A shows a side view of an electrochemical device
according to one exemplary embodiment of the present invention. In
this embodiment, a first contact 101 is coupled with bonding layer
110 with a portion of the first contact 101 extending past the
bonding layer 110. The bonding layer 110 may, for example, be
bonded with the cell structure 115. A semiconducting surface or the
conductive or insulating surface of a semiconductor device 105 is
placed under the battery cell structure 115. An insulating surface
of the semiconductor device 105 may be, for example, an insulating
packaging surface of a semiconductor device or an upper insulating
surface the semiconductor device. A conductive surface may include,
for example, a conductive contact pad, a conductive line,
conductive via or other conductive layer formed on or at the device
surface. A conductive surface also may be formed together with an
insulating surface, such as a conductive surface formed on a
packaging surface of a semiconductor device. Shown embedded within
the bonding layer 110 is a first embedded conductor 120. This first
embedded conductor 120, for example, creates a selectively
conductive bonding layer. A selectively conductive bonding layer
110 permits conduction from the cell structure 115 through the
bonding layer 110 to the first contact 101 at specific points, and
yet provides insulation between the first contact 101 and the
semiconducting surface or the conductive or insulating surface of a
semiconductor device 105. Other types of battery cell structures
may be also be included.
[0026] The electrochemical device may have a second embedded
conductor 121 that selectively creates an electrical contact
between the first contact 101 and the semiconducting surface or the
conductive or insulating packaging surface of a semiconductor
device 105. In this case, the semiconducting surface or the
conductive or insulating surface of a semiconductor device 105 must
be selectively insulating between the contacts points at which the
first embedded conductor 120 and the second embedded conductor 121
meet the semiconducting surface or the conductive or insulating
(e.g., packaging) surface of a semiconductor device 105.
[0027] FIG. 1B shows a side view of an electrochemical device
according to an exemplary embodiment of the present invention. In
this embodiment, a first contact 101 is coupled with the battery
cell structure 115. A bonding layer 110 is coupled to the battery
cell structure 115 and a portion of the first contact 101, which
extends past the bonding layer 110, A semiconducting surface or the
conductive or insulating surface of a semiconductor device 105 is
coupled with the bonding layer 110. Shown embedded within the
bonding layer 110 is the first embedded conductor 120. This first
embedded conductor 120, for example, creates a selectively
conductive bonding layer. A selectively conductive bonding layer
110 permits conduction from the cell structure 115 through the
bonding layer 110 to the semiconducting surface or the conductive
or insulating (e.g., packaging) surface of a semiconductor device
105 at specific points, and yet provides insulation between the
first contact 101 and the semiconducting surface or the conductive
or insulating surface of a semiconductor device 105. The
electrochemical device may have a second embedded conductor 121
that selectively creates an electrical contact between the first
contact 101 and the semiconducting surface or the conductive or
insulating surface of a semiconductor device 105. In this case the
semiconducting surface or the conductive or insulating surface of a
semiconductor device 105 must be selectively insulating between the
contact points at which the first embedded conductor 120 and the
second embedded conductor 121 meet the semiconducting surface or
the conductive or insulating packaging surface of a semiconductor
device 105. The first embedded conductor 120 and the second
embedded conductor 121 may be placed within the bonding layer 110
in many different ways. For example, a metal tab, a metal wire, a
metal strip, a metal ribbon, multiple metal wires, multiple metal
strips, multiple metal ribbons, a metal wire mesh, perforated metal
foil, perforated metal, a metal coating applied to the adhesive
layer, a metallic disk, a metallically coated fiberglass or
combinations thereof may be used. In each of these examples, the
first embedded conductor 120 and the second embedded conductor 121
can provide electrical conduction between the cell structure 115
and the first contact 101 and the boding layer 110 provides
insulation between the first contact 101 and the semiconducting
surface or the conductive or insulating surface of a semiconductor
device 105. In some embodiments, the embedded conductors 120 and
121 may be woven within the bonding layer 110. The embedded
conductors 120 and 121 may be, for example, disks embedded within
the bonding layer 110. In some embodiments slits within the bonding
layer 110 may be made in order to weave or place the embedded
conductors 120 and 121 through the bonding layer 110. Also, for
example, holes or other means may be used to place the embedded
conductors 120 and 121 through the bonding layer 110.
[0028] In another exemplary embodiment of the present invention, a
reinforcement layer may be placed within the bonding layer. For
example, a fiberglass material may cover half of one surface of the
bonding layer, woven through the layer and then cover the other
half of the bonding layer. Such a layer of fiberglass without a
conductive coating would insulate the materials placed between. The
fiberglass may be coated in a localized area with a conductive
material. Such conductive coatings can coat the fiberglass area in
the top and bottom surface of the bonding layer. In such an
embodiment, for example, the fiberglass may conduct between the
upper contact and the cell. Conductive material may be disposed on
the fiberglass using ink jet, silk screen, plasma deposition,
e-beam deposition, spray and/or brush methods. Other materials may
be used rather than fiberglass, such as, for example, Kevlar.RTM.,
plastic, glass or other insulating materials.
[0029] Another exemplary embodiment of the present invention may
provide for selective contact between the first contact and the
battery cell structure through holes in the bonding layer. In such
an embodiment, holes in the bonding layer may allow the first
contact and battery cell structure to remain in contact. The layers
may be, for example, pressed together to create a contact.
Alternatively, conductive glues or inks may be applied in or near
the hole area in the bonding layer to make the contact between the
layers. Lithium may also be used.
[0030] The embedded conductors 120 and 121 and/or first contact,
for example, may be made of gold, platinum, stainless steel,
titanium, vanadium, chromium, manganese, iron, cobalt, nickel,
copper zirconium, niobium, molybdenum, hafnium, tantalum, tungsten,
aluminum, indium, tin, silver, carbon, bronze, brass, beryllium, or
oxides, nitrides, carbides, and alloys thereof. The first contact
may be a metal foil, for example, may be made of stainless steel or
any other metallic substance having the necessary or suitable
characteristics and properties such as a requisite amount of
conductivity. The metal foil may preferably comprise a solderable
alloy, for instance, alloys of copper, nickel, or tin. The first
contact may be, for example, less than 100 microns thick, less than
50 microns thick, or less than 25 microns thick.
[0031] The electrochemical device 115 may include a cathode, anode
and electrolyte. For example, the cathode may comprise LiCo0.sub.2,
the anode may comprise Lithium and the electrolyte may comprise
LIPON. Other electrochemical devices may be used as needed.
[0032] The electrochemical device 115 may be coupled with the
semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 105 in a number of ways. In one
embodiment, the electrochemical device, for example, may be coupled
with the semiconducting surface or the conducting or insulating
surface of semiconductor device 105 using glue. Glue, as used in
this application, extends to any material that may adhere the
electrochemical device 115 to the semiconducting surface or the
conducting or insulating surface of a semiconductor device 105. The
glue may create either a mechanical or chemical bond between the
two layers. Glue may also include chemically bonding the two layers
without introducing another material or layer. Glue, for example,
may include but is not limited to cement glue and resin glue. The
glue may be electrically conducting, semi-conducting, or
insulating.
[0033] In another exemplary embodiment, the semiconducting surface
or the conductive or insulating (e.g., packaging) surface of a
semiconductor device 105 acts as a substrate for the battery. The
semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 105 is provided and the
electrochemical device 115 may be deposited thereon. The
electrochemical device 115 may also be glued to the semiconducting
surface or the conductive or insulating packaging surface of a
semiconductor device 105.
[0034] In an exemplary embodiment, a LiCo0.sub.2 cathode layer is
deposited on the semiconducting surface or the conducting or
insulating surface of a semiconductor device 105. A number of
deposition techniques are known in the art, these include, but are
not limited to reactive or non-reactive RF magnetron sputtering,
reactive or non-reactive pulsed DC magnetron sputtering, reactive
or non-reactive DC diode sputtering, reactive or non-reactive
thermal (resistive) evaporation, reactive or non-reactive electron
beam evaporation, ion-beam assisted deposition, plasma enhanced
chemical vapor deposition, or deposition methods, which may
include, for example, spin coating, ink-jetting, thermal spray
deposition, dip coating or the like. As part of the fabrication
process, for example, the cathode may be annealed using a thermal
anneal such as anneal at lower temperatures, anneal at higher
temperatures, or by using convection furnaces or rapid thermal
anneal methods. Another or an alternative post-deposition anneal
may include laser annealing to improve the crystallization of the
LiCo0.sub.2 layer so as to fine-tune and optimize its chemical
properties, such as its electrochemical potential, its energy, its
power performance, and its reversible lattice parameters on
electrochemical and thermal cycling.
[0035] Following deposition of the cathode layer, an electrolyte
may be deposited on the cathode, followed by an anode. Again, these
layers may be deposited by any of a number of processes common in
the art. In one specific embodiment, once the electrochemical
device 115 has been deposited on the semiconducting surface or the
conducting or insulating surface of a semiconductor device 105, a
bonding layer 110 may be placed between the electrochemical device
and a first electrical contact 101. In this specific embodiment
shown in FIG. 1A, a metal encapsulate layer 101 may also be the
first contact. In another specific embodiment, once the
electrochemical device 115 has been deposited on the first
electrical contact 101, a bonding layer 110 may be placed between
the electrochemical device 115 and the semiconducting surface or
the conducting or insulating surface of a semiconductor device 105.
In this specific embodiment shown in FIG. 1B, a metal encapsulate
layer 101 may also be the first contact. As described above, the
first contact may be a metal foil, for example, may be made of
stainless steel or any other metallic substance having the
necessary characteristics and properties such as a requisite amount
of conductivity. The metal foil may preferably comprise a
solderable alloy, for instance, alloys of copper, nickel, or tin.
The first contact may be, for example, less than 100 microns thick,
less than 50 microns thick, or less than 25 microns thick.
[0036] The bonding layer 110 may include, for example, an adhesive
material, an insulating material, polymeric material, glass,
Kevlar.RTM., reinforcement materials, and fiberglass. The embedded
conductors 120 and 121 may include, for example, a tab, a wire, a
metal strip, a metal ribbon, multiple wires, multiple metal strips,
multiple metal ribbons, a wire mesh, perforated metal, a metal
coating applied to the adhesive layer, and a disk.
[0037] FIG. 2 shows a second embodiment of a thin film battery on a
chip. In this embodiment the battery may include a semiconducting
surface or the conductive or insulating packaging surface of a
semiconductor device 105, a cathode layer 145 deposited on the
semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 105, an electrolyte 150, an anode
165, a modulating layer 160, an encapsulate 155, an anode current
collector 170 and an insulator 175. For example, the cathode 145
may comprise LiCo0.sub.2, the anode 160 may comprise Lithium and
the electrolyte 150 may comprise LIPON. Other electrochemical
devices may be used as needed. The encapsulate 155 may comprise a
ceramic-metal composite laminate of a multiple of alternating
layers of Zirconium Nitride and Zirconium or Titanium Nitride and
Titanium.
[0038] The electrochemical device which may include the cathode
145, electrolyte 150 and anode 155, may be semiconducting surface
or the conductive or insulating packaging surface of a
semiconductor device 105 in a number of ways. In one embodiment,
the electrochemical device, for example, may be coupled with the
substantially conductive, semiconducting surface or the conductive
packaging surface of a semiconductor device 105 using glue. Glue,
as used in this application, extends to any material that may
adhere parts of the electrochemical device to the semiconducting
surface or the conductive or insulating packaging surface of a
semiconductor device 105. The glue may create either a mechanical
or chemical bond between the two layers. Glue may also include
chemically bonding the two layers without introducing another
material or layer. The glue may be electrically conductive in order
to use the semiconducting surface or the conductive or insulating
packaging surface of a semiconductor device 105 as current
collector. Glue, for example, may include but is not limited to
electrically conductive cement glue and resin glue.
[0039] The cathode 145 may also be deposited directly on the
semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 105. In a specific embodiment, a
LiCo0.sub.2 cathode layer is deposited on semiconducting surface or
the conductive or insulating packaging surface of a semiconductor
device 105. A number of deposition techniques are known in the art,
these include, but are not limited to reactive or non-reactive RF
magnetron sputtering, reactive or non-reactive pulsed DC magnetron
sputtering, reactive or nonreactive DC diode sputtering, reactive
or non-reactive thermal (resistive) evaporation, reactive or
non-reactive electron beam evaporation, ion-beam assisted
deposition, plasma enhanced chemical vapor deposition, deposition
methods, which may include, for example, spin coating, ink jetting,
thermal spray deposition, dip coating or the like. As part of the
fabrication process for example, a post-deposition laser anneal may
be used to improve the crystallization of the cathode layer 145 in
order to fine-tune and optimize its chemical properties, such as
its electrochemical potential, its energy, its power performance,
and its reversible lattice parameters on electrochemical and
thermal cycling. Examples of methods used to deposit LiCo0.sub.2
are disclosed in U.S. patent application Ser. No. 11/557,383, filed
on Nov. 7, 2006, which is incorporated herein by reference in its
entirety.
[0040] The semiconducting surface or the conductive or insulating
packaging surface of a semiconductor device in the above
embodiments may be part of any integrated circuit and may include
memory devices, processors or other logic circuits.
[0041] Another embodiment of the present invention includes a
battery deposited on a flexible printed circuit board including,
for example, a first electrical contact; a bonding layer coupled
with the first electrical contact and having an embedded conductor;
at least one battery cell structure; and a flexible printed circuit
board. A bonding layer and the at least one battery cell structure
may be sandwiched between the first contact layer and the flexible
printed circuit board. The bonding layer may be selectively
conductive through the embedded conductor. The battery cell
structure may further be in selective electrical contact with the
first electrical contact via the embedded conductor.
[0042] FIG. 3A shows a side view of an electrochemical device
according to another embodiment of the present invention. In this
embodiment, a first contact 301 is coupled with bonding layer 310
with a portion of the first contact 301 extending past the bonding
layer 310. The bonding layer 310 may, for example, be bonded with
the cell structure 315. A flexible printed circuit board 305 is
placed under the battery cell structure 315. Shown embedded within
the bonding layer 310 is a first embedded conductor 320. This first
embedded conductor 320, for example, creates a selectively
conductive bonding layer. A selectively conductive bonding layer
310 permits conduction from the cell structure 315 through the
bonding layer 310 to the first contact 301 at specific points, and
yet provides insulation between the first contact 301 and the
flexible circuit board 305. Also shown embedded within the bonding
layer 310 is the second embedded conductor 321. This second
conductor, for example, further creates a selectively conductive
bonding layer. The further selectively conductive boding layer 310
permits conduction from the flexible printed circuit board 305
through the bonding layer 310 to the first contact 301 at specific
points, and yet provides insulation between the first contact 301
and the flexible printed circuit board 305. Other types of battery
cell structures may be also be included.
[0043] FIG. 3B shows a side view of an electrochemical device
according to one exemplary embodiment of the present invention. In
this embodiment, a first contact 301 is coupled with the battery
cell structure 315. A bonding layer 310 is coupled to the battery
cell structure 315 and a portion of the first contact 301, which
extends past the bonding layer 310. A flexible printed circuit
board 305 is coupled with the bonding layer 310. Shown embedded
within the bonding layer 310 is the first embedded conductor 320.
This first embedded conductor 320, for example, creates a
selectively conductive bonding layer. A selectively conductive
bonding layer 310 permits conduction from the cell structure 315
through the bonding layer 310 to the flexible printed circuit board
305 at specific points, and yet provides insulation between the
first contact 301 and the flexible printed circuit board 305. The
electrochemical device may have a second embedded conductor 321
that selectively creates an electrical contact between the first
contact 301 and the flexible printed circuit board 305. In this
case, the flexible printed circuit board 305 must be selectively
insulating between the contacts points at which the first embedded
conductor 320 and the second embedded conductor 321 meet the
flexible printed circuit board 305.
[0044] FIG. 3C is a top view of an exemplary electrochemical device
integrated with a flexible circuit board 305, such as the exemplary
devices described above with respect to FIGS. 3A and 3B. As shown
in FIG. 3C, conductive traces 330, 331 are formed on a surface of
the circuit board 305. Other types of conductive surfaces, such as
contact pads, wiring, exposed conductive vias etc., or combinations
thereof may be provided on the circuit board surface to receive the
electrochemical device. In the plan view, the first embedded
conductor 320 is shown passing through bonding layer 310 to make
electrical contact with conductive trace 330, and the second
embedded conductor 321 is shown passing through bonding layer 310
to make electrical contact with conductive trace 331. It should be
appreciated that an analogous arrangement can be achieved with
respect to the examples including a semiconducting surface or the
conductive or insulating packaging surface of a semiconductor
device, as described above with respect to FIGS. 1A and 1B
[0045] The flexible circuit board 305 may comprise, for example,
multiple circuit board layers with and without traces, single or
double sided, semi-rigid, a film, and/or a polyimide film.
[0046] The embedded conductors 320 and 321 may be placed within the
bonding layer 310 in many different ways. For example, a metal tab,
a metal wire, a metal strip, a metal ribbon, multiple metal wires,
multiple metal strips, multiple metal ribbons, a metal wire mesh,
perforated metal foil, perforated metal, a metal coating applied to
the adhesive layer, a metallic disk, a metallically coated
fiberglass or combinations thereof may be used. In each of these
examples, the first embedded conductor 320 can provide selective
electrical conduction between the cell structure 315 and the first
contact 301 or the flexible printed circuit board 305, and yet
provide insulation between the battery cell structure 315 and the
first contact 301 or the flexible printed circuit board 305. Also
in each of these examples, the second embedded conductor 321 can
provide selective electrical conduction between the first contact
301 and the flexible printed circuit board 305 and yet provide
insulation between the first contact 301 and the flexible printed
circuit board 305. In some embodiments the first embedded conductor
320 may be woven within the bonding layer 310. The first embedded
conductor 320 may be, for example, disks embedded within the
bonding layer 310. In some embodiments slits within the bonding
layer 310 may be made in order to weave or place the first embedded
conductor 320 through the bonding layer 310. Also, for example,
holes or other means may be used to place the first embedded
conductor 320 through the bonding layer 310. In some embodiments
the second embedded conductor 321 may be woven within the bonding
layer 310. The second embedded conductor 321 may be, for example,
disks embedded within the bonding layer 310. In some embodiments
slits within the bonding layer 310 may be made in order to weave or
place the second embedded conductor 321 through the bonding layer
310. Also, for example, holes or other means may be used to place
the second embedded conductor 321 through the bonding layer
310.
[0047] The electrochemical device 315 may include a cathode, anode
and electrolyte. For example, the cathode may comprise LiCo0.sub.2,
the anode may comprise Lithium and the electrolyte may comprise
LIPON. Other electrochemical devices may be used as needed.
[0048] The electrochemical device 315 may be coupled with the
flexible printed circuit board 305 in a number of ways. In one
embodiment, the electrochemical device 315, for example, may be
coupled with the flexible printed circuit board 305 using glue.
Glue, as used in this application, extends to any material that may
adhere the electrochemical device 315 to the flexible printed
circuit board 305. The glue may create either a mechanical or
chemical bond between the two layers. Glue may also include
chemically bonding the two layers without introducing another
material or layer. Glue, for example, may include but is not
limited to cement glue and resin glue. The glue may be electrically
conducting, semi-conducting, or insulating.
[0049] The electrochemical device 315 may be coupled with the first
electrical contact 301 in a number of ways. In one embodiment, the
electrochemical device 315, for example, may be coupled with the
first electrical contact 301 using glue. Glue, as used in this
application, extends to any material that may adhere the
electrochemical device 315 to the first electrical contact 301. The
glue may create either a mechanical or chemical bond between the
two layers. Glue may also include chemically bonding the two layers
without introducing another material or layer. Glue, for example,
may include but is not limited to cement glue and resin glue. The
glue may be electrically conducting, semi-conducting, or
insulating.
[0050] In another embodiment the flexible printed circuit board 305
acts as a substrate for the battery, which may be deposited
thereon.
[0051] In another embodiment the first electrical contact 301 acts
as a substrate for the battery, which may be deposited thereon.
[0052] In another embodiment the flexible printed circuit board 305
acts as an encapsulate for the battery.
[0053] In another embodiment the first electrical contact 301 acts
as an encapsulate for the battery.
[0054] In another exemplary embodiment shown in FIG. 4A, a thin
film battery is provided on a semiconducting surface or the
conductive or insulating surface of a semiconductor device with a
barrier layer there between. Elements depicted in FIG. 4A like
those above in FIG. 1A are shown having the same reference numbers.
In this embodiment, a first contact 101 is coupled with bonding
layer 110 with a portion of the first contact 101 extending past
the bonding layer 110. The bonding layer 110 may, for example, be
bonded with the cell structure 115. A semiconducting surface or the
conductive or insulating (e.g., packaging) surface of a
semiconductor device 105 with a barrier layer 107 is placed under
the battery cell structure 115.
[0055] In this embodiment, barrier layer 107 may include, for
example, titanium nitride. The barrier layer 107 may also comprise
a semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 105. A conductive surface may
include, for example, a conductive contact pad, a conductive line,
conductive via or other conductive layer formed on or at the device
surface. A conductive surface also may be formed together with an
insulating surface, such as a conductive surface formed on a
packaging surface of a semiconductor device. An insulating surface
of the semiconductor device 105 may be, for example, an insulating
packaging surface of a semiconductor device or an upper insulating
surface the semiconductor device. Shown embedded within the bonding
layer 110 is conductor 120. This conductor 120, for example,
creates a selectively conductive bonding layer. A selectively
conductive bonding layer 110 permits conduction from the cell
structure 115 through the bonding layer 110 to the first contact
101 at specific points, and yet provides insulation between the
first contact 101 and the barrier layer 107. Other types of battery
cell structures may be also be included.
[0056] The electrochemical device 115 may be coupled with the
semiconducting surface or the conductive or insulating (e.g.,
packaging) surface of a semiconductor device 105 and barrier layer
107 in a number of ways. In one embodiment, the electrochemical
device, for example, may be coupled with the barrier layer using
glue. Glue, as used in this application, extends to any material
that may adhere the electrochemical device 115 to the barrier layer
107. The glue may create either a mechanical or chemical bond
between the two layers. Glue may also include chemically bonding
the two layers without introducing another material or layer. Glue,
for example, may include but is not limited to cement glue and
resin glue. The glue may be electrically conducting,
semi-conducting, or insulating.
[0057] In another exemplary embodiment the semiconducting surface
or the conductive or insulating packaging surface of a
semiconductor device 105 acts as a substrate for the battery. The
semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 105 is provided and the barrier
layer 107 may be deposited thereon. The barrier layer 107 may also
be glued to the semiconducting surface or the conductive or
insulating packaging surface of a semiconductor device 105. Once
the barrier layer 107 and the substrate 105 have been prepared, the
electrochemical device 115 may be deposited directly on the barrier
layer 107.
[0058] In an exemplary embodiment, a LiCo0.sub.2 cathode layer is
deposited on the barrier layer 107 by way of methods described
above.
[0059] In yet another exemplary embodiment shown in FIG. 4B, a thin
film battery is provided on a flexible circuit board. Elements
depicted in FIG. 4B like those above in FIG. 3A are shown having
the same reference numbers. In this embodiment, a first contact 301
is coupled with bonding layer 310 with a portion of the first
contact 301 extending past the bonding layer 310. The bonding layer
310 may, for example, be bonded with the cell structure 315. A
flexible printed circuit board 305, such as described above, and a
barrier layer 307 is placed under the battery cell structure 315.
In this embodiment, the barrier layer 307 may, for example, include
titanium nitride. Shown embedded within the bonding layer 310 is
conductor 320. This conductor 320, for example, creates a
selectively conductive bonding layer. A selectively conductive
bonding layer 310 permits conduction from the cell structure 315
through the bonding layer 310 to the first contact 301 at specific
points, and yet provides insulation between the first contact 301
and the barrier layer 307. The conductor 320 may be provided within
the bonding layer 310 as described above. In each of these
examples, the conductor 320 can provide electrical conduction
between the cell structure 315 and the first contact 301 and yet
provide insulation between the first contact 301 and the barrier
layer 307.
[0060] The electrochemical device 315 may be coupled with the
semiconducting surface or the conductive or insulating packaging
surface of a semiconductor device 305 and barrier layer 307 in a
number of ways. In one embodiment, the electrochemical device, for
example, may be coupled with the barrier layer using glue. Glue, as
used in this application, extends to any material that may adhere
the electrochemical device 315 to the barrier layer 307. The glue
may create either a mechanical or chemical bond between the two
layers. Glue may also include chemically bonding the two layers
without introducing another material or layer. Glue, for example,
may include but is not limited to cement glue and resin glue. The
glue may be electrically conducting, semi-conducting, or
insulating.
[0061] In another embodiment the flexible printed circuit board 305
acts as a substrate for the battery and the barrier layer 307 may
be deposited thereon. The barrier layer 307 may also be glued to
the flexible printed circuit board 305. Once the barrier layer 307
and the printed circuit board 305 have been prepared, the
electrochemical device 315 may be deposited directly on the barrier
layer 307.
[0062] While FIGS. 4A and 4B show only one conductor 120, 320,
respectively, it is to be understood that exemplary embodiments
also may include at least one second conductor, such as conductors
121, 321, respectively described above in connection with FIGS. 1A
and 3A. Further, electrical connection between the first contact
101, 301 and the underlying semiconducting surface, conductive or
insulating surface of a semiconductor device, or a flexible circuit
board can be made by conductors 121, 321 through the bonding and/or
barrier layers.
[0063] The above-discussed exemplary embodiments may also include
multiple electrochemical devices stacked upon a semiconducting
surface or the conductive or insulating (e.g., packaging) surface
of a semiconductor device.
[0064] The above-discussed exemplary embodiments may also include
multiple electrochemical devices stacked upon the first electrical
contact 301.
[0065] The present exemplary embodiments provide alternative
schemes to encapsulate the chemically and mechanically sensitive
layers of electrochemical devices, which are less expensive than
prior encapsulation schemes using gold foil. The above exemplary
embodiments also avoid problems of other prior schemes relating to
blow out of the seals of a metal and plastic pouch encapsulating an
electrochemical device resulting from temperature changes, which
cause the gas within the metal and plastic pouch to expand and/or
contract.
[0066] The exemplary embodiments described herein also provide a
rechargeable secondary battery directly fabricated on a
semiconductor device such as an integrated circuit. Such batteries
provide power during times when the circuit is powered off and are
quickly and easily recharged when power resumes. Critical circuitry
may benefit from localized power provided by such batteries. The
exemplary embodiments also provide for less expensive and more
reliable encapsulating approaches, and better approaches to
providing electrically conductive contacts, including encapsulation
that is substantially thinner than known encapsulation methods. The
exemplary embodiments also provide flexible integrated circuits
and/or flexible printed circuit boards with thin film flexible
batteries coupled thereon.
[0067] Although the above examples describe a conductive material
provided in an opening in the bonding layer, such as the slit, it
should be appreciated that electrical contact between the battery
cell structure 115, 315 and first electrical contact 101, 301 may
be provided by a number of other ways. For example, embedding a
conductive powder within an adhesive forming the bonding layer 110,
310 may provide electrical conduction between the cell structure
115, 315 and the first contact 101, 301. For example, a conductive
powder such as a metallic powder (e.g., nickel powder) can be
embedded in an adhesive bonding layer 110, 310 at one or more
selected areas within an adhesive bonding layer 110, 310 and
between the contact 101, 301 and the battery cell structure 115,
315. Those skilled in the art will appreciate other conductive
materials that may be provided for the selective conduction, such
as conductive balls, slugs, wiring mesh etc. selectively provided
within an adhesive. The ways to achieve electrical conduction
between the battery cell structure 115, 315 and the first contact
101, 301 and yet provide insulation between the contacts and
battery cell structure, should not be considered as limited to the
examples explained herein.
[0068] The same holds true for the electrical contact between the
battery cell structure 115, 315 and the semiconducting surface or
the conductive or insulating packaging surface of a semiconductor
device 105 or the flexible printed circuit board 305. The same also
holds true for the electrical contact between the first contact
101, 301 and the semiconducting surface or the conductive or
insulating packaging surface of a semiconductor device 105 or the
flexible printed circuit board 305.
[0069] Additionally, it should be appreciated that the
electrochemical device may comprise a discrete device (e.g., fully
packaged with its own substrate and own encapsulation) on a
semiconductor surface, a conducting or insulating surface of a
semiconductor device or a flexible printed circuit board. For
example, prior to its integration onto the semiconducting surface
or a conductive or insulating surface of a semiconductor device or
into or onto a flexible printed circuit board, the electrochemical
device may be fabricated as a discrete device, and then integrated
as a whole together with its substrate and its encapsulation.
[0070] The embodiments described above are exemplary only. One
skilled in the art may recognize variations from the embodiments
specifically described here, which are intended to be within the
scope of this disclosure. As such, the invention is limited only by
the following claims. Thus, it is intended that the present
invention cover the modifications of this invention provided they
come within the scope of the appended claims and their
equivalents.
* * * * *