Microbattery assembly

Abstract

The disclosure relates to microbattery devices and assemblies. In an embodiment, a device includes a plurality of microbatteries, a first flexible encapsulation film, and a second flexible encapsulation film. Each of the microbatteries includes a first contact terminal and a second contact terminal spaced apart from one another. The first flexible encapsulation film includes a first conductive layer electrically coupled to the first contact terminal of each of the microbatteries, and a first insulating layer on the first conductive layer. The second flexible encapsulation film includes a second conductive layer electrically coupled to the second contact terminal of each of the microbatteries, and a second insulating layer on the second conductive layer.

1 . A method, comprising:
 forming a first flexible film, the first flexible film including a first conductive layer, a first insulating layer on the first conductive layer, and a first adhesive layer on the first insulating layer;   forming a second flexible film, the second flexible film including a second conductive layer, a second insulating layer on the second conductive layer, and a second adhesive layer on the second conductive layer;   forming a plurality of cavities in the first adhesive layer and the second adhesive layer; and   positioning a plurality of microbatteries in the plurality of cavities, each of the microbatteries including a first contact terminal electrically coupled to the first conductive terminal and a second contact terminal electrically coupled to the second conductive layer.   
     
     
         2 . The method of  claim 1 , comprising:
 forming a plurality of first cavities by etching the second adhesive layer;   positioning a respective microbattery in each first cavity, the second contact terminal of the microbattery electrically coupled to the second conductive layer in the first cavity;   forming a plurality of second cavities by etching the first adhesive layer; and   attaching the first flexible film onto the second flexible film, with the first adhesive layer facing the second adhesive layer, each microbattery being positioned in a second cavity with the first contact terminal of each microbattery electrically coupled to the first conductive layer in the second cavity.   
     
     
         3 . The method of  claim 2 , comprising:
 attaching a third flexible film to the first flexible film, the third flexible film including an inductor on the first flexible film and a third insulating layer on the inductor.   
     
     
         4 . The method of  claim 3 , comprising:
 electrically coupling first and second input terminals of an AC/DC converter to the inductor; and   electrically coupling first and second output terminals of the AC/DC converter to the first and the second contact terminals of the microbatteries.   
     
     
         5 . A device, comprising:
 a plurality of microbatteries, each of the microbatteries including a first contact terminal and a second contact terminal;   a first flexible encapsulation film including:
 a plurality of portions of a first conductive layer electrically coupled to the first contact terminal of each of the microbatteries, each portion being spaced from an adjacent one of the plurality of portions; and 
   a second flexible encapsulation film including:
 a plurality of portions of a second conductive layer electrically coupled to the second contact terminal of each of the microbatteries, each portion being spaced from an adjacent one of the plurality of portions. 
   
     
     
         6 . The device of  claim 5  wherein a first one of the plurality of portions of the first conductive layer is coupled to a first one and a second one of the plurality of microbatteries. 
     
     
         7 . The device of  claim 6  wherein a first one of the plurality of portions of the second conductive layer is coupled to the second one and a third one of the plurality of microbatteries. 
     
     
         8 . The device of  claim 7  wherein the first one of the plurality of portions of the first conductive layer is coupled to the first terminal of the first and second ones of the plurality of microbatteries and the first one of the plurality of portions of the second conductive layer is coupled to the second terminal of the second and third ones of the plurality of microbatteries. 
     
     
         9 . The device of  claim 5  wherein the first flexible encapsulation film includes a first adhesive layer that is between adjacent ones of the plurality of microbatteries and is between adjacent portions of the first conductive layer. 
     
     
         10 . The device of  claim 9  wherein the second flexible encapsulation film includes a second adhesive layer that is between adjacent ones of the plurality of microbatteries and is between adjacent portions of the second conductive layer. 
     
     
         11 . The device of  claim 10  wherein the plurality of microbatteries are coupled together in series. 
     
     
         12 . A device, comprising:
 a plurality of microbatteries, each of the microbatteries including a first contact terminal, a second contact terminal, and an electrolyte layer;   a first flexible film having a first conductive layer and a first insulating layer on the first conductive layer, the first conductive layer including a plurality of discontinuous first portions; and   a second flexible film having a second conductive layer and a second insulating layer on the second conductive layer, the second conductive layer including a plurality of discontinuous second portions; and   an inductor that includes third flexible film on the first flexible film, the third flexible film having a third conductive layer and a third insulating layer on the third conductive layer.   
     
     
         13 . The device of  claim 12  wherein the first conductive layer is coupled to the first contact terminal of each of the microbatteries and the second conductive layer is coupled to the second contact terminal of each of the microbatteries. 
     
     
         14 . The device of  claim 13  wherein the first flexible encapsulation film includes a first adhesive layer that is between adjacent ones of the plurality of microbatteries and is between adjacent first portions of the first conductive layer. 
     
     
         15 . The device of  claim 14  wherein the second flexible encapsulation film includes a second adhesive layer that is between adjacent ones of the plurality of microbatteries and is between adjacent second portions of the second conductive layer. 
     
     
         16 . The device of  claim 12  wherein the plurality of microbatteries are electrically coupled to one another in series.