Thin film pattern layer battery systems

Abstract

A battery assembly can be formed on a base layer provided on a substrate, with a thin film battery stack including an anode layer, a cathode layer, and an electrolyte layer between the anode and cathode layers. The thin film battery stack can be attached to a pattern film layer with holes for electrical connection to the anode and cathode layers.

We claim: 
     
         1 . A battery system comprising:
 a plurality of thin film battery cells arranged in a stacked configuration forming a thin film battery stack, each of the thin film battery cells comprising at least an anode layer, a cathode layer, a cathode current collector layer, an anode current collector layer, and an electrolyte layer between the anode layer and the cathode layer; and   a patterned layer, attached to the thin film battery stack, having pattern holes configured for electrical power connection to the thin film battery stack, the pattern holes including: a first pattern hole that physically exposes the cathode current collector layer, and a second pattern hole that physically exposes the anode current collector layer.   
     
     
         2 . The battery system of  claim 1 , wherein the first pattern hole and the second pattern hole are on a plane defined by the patterned layer. 
     
     
         3 . The battery system of  claim 1 , wherein:
 the cathode layer has a crystalline structure characterized by a phase transition temperature: and   the patterned layer is not thermally stable at the phase transition temperature.   
     
     
         4 . The battery system of  claim 1 , wherein:
 the cathode current collector layer is adjacent the cathode layer; and   at least a pair of the cathode current collector layers are positioned in an adjacent and electrically coupled relationship within the stacked configuration.   
     
     
         5 . The battery system of  claim 1 , wherein:
 at least a pair of the cathode layers are positioned in an adjacent and electrically coupled relationship within the stacked configuration; and   the cathode current collector layer is formed as an electrically conducting bond between the adjacent pair of cathode layers.   
     
     
         6 . The battery system of  claim 1 , wherein:
 at least a pair of the anode layers are positioned in an adjacent and electrically coupled relationship within the stacked configuration; and   the anode current collector layer is formed as an electrically conductive bond between the adjacent pair of anode layers.   
     
     
         7 . The battery system of  claim 1 , further comprising an encapsulant disposed about the thin film battery stack on the patterned layer. 
     
     
         8 . A device comprising:
 a display;   a controller coupled to the display; and   a battery assembly coupled to the controller and configured for powering the display, the battery assembly comprising:   a plurality of thin film battery cells arranged in a stacked configuration forming a thin film battery stack, each of the thin film battery cells comprising at least an anode layer, a cathode layer, a cathode current collector layer, an anode current collector layer, and an electrolyte layer between the anode layer and the cathode layer; and   a patterned layer, attached to the thin film battery stack, having pattern holes configured for electrical power connection to the thin film battery stack, the pattern holes including: a first pattern hole that physically exposes the cathode current collector layer, and a second pattern hole that physically exposes the anode current collector layer.   
     
     
         9 . The device of  claim 8 , wherein the anode current collector layer and/or the cathode current collector layer comprise a conducting adhesive. 
     
     
         10 . The device of  claim 8 , wherein the patterned layer is a thin film. 
     
     
         11 . The device of  claim 8 , wherein the patterned layer comprises one or more of plastics, polymers, metals, glass, ceramic or refractory materials. 
     
     
         12 . The device of  claim 8 , wherein a thickness of the patterned layer is between about 20 microns and about 10 microns. 
     
     
         13 . The device of  claim 8 , wherein a thickness of the patterned layer is between about 10 microns and about 5 microns. 
     
     
         14 . The device of  claim 8 , wherein a thickness of the patterned layer is less than about 5 microns. 
     
     
         15 . The device of  claim 8 , wherein the cathode layer and/or the cathode current collector layer comprise lithium and cobalt. 
     
     
         16 . The device of  claim 8 , wherein the anode layer and/or the anode current collector layer comprise one or more of lithium, lithium cobalt oxide, lithium iron phosphate, lithium metal phosphates, lithium manganese oxide, carbon, graphite, or graphite infused with lithium ions. 
     
     
         17 . The device of  claim 8 , wherein the electrolyte layer comprises one or more of ethylene carbonate containing lithium ion complexes or diethyl carbonate containing lithium ion complexes. 
     
     
         18 . The device of  claim 8 , wherein:
 the electrolyte layer further comprises a separator material; and   the separator material comprises one or more of polyethylene lithium ion transport materials, lithium phosphate, lithium phosphorous, lithium phosphorous oxynitride (LiPON), or carbon nanotube materials.   
     
     
         19 . The device of  claim 8 , further comprising an encapsulant disposed about the thin film battery stack on the patterned layer. 
     
     
         20 . The device of  claim 8 , further comprising a battery pouch, wherein the battery assembly is disposed within the battery pouch.