Manufacturing method of low-power electronic band for tracking articles

Abstract

Wireless communication bands, distributors thereof, and methods of use of wireless bands and distributors in asset tracking applications are disclosed. The wireless communication tape may be manufactured in an ultra-thin form factor by laminating a stack of layers to impart functionality to the wireless communication tape. Methods of use and operation of a wireless communication band are disclosed to conserve battery resources of the communication band.

Description

Technical Field

[0001] The present invention relates generally to the field of wireless communications, and more particularly to ultra-thin Bluetooth tags for asset tracking. Background Art

[0002] The ability to track objects can have many business uses, including cargo tracking and logistics in the supply chain. For example, almost every business that maintains inventory could use an improved system to track objects within its inventory. Summary of the invention

[0003] In one aspect, a wireless tape including wireless tracking tags is disclosed that can be formed in a roll-to-roll process and later separated to form individual wireless tracking tags. The wireless tape includes: a polyester substrate; an interconnect layer coated on the polyester substrate and patterned to electrically couple a plurality of electrical circuits, wherein the electrical circuits are formed and / or bonded on the interconnect layer and include an RF processor configured to broadcast a beacon at a broadcast frequency, an RF communications circuit; and a battery including cathode and anode layers and a battery pouch disposed on the interconnect layer, wherein the interconnect layer includes a cathode layer, and wherein the RF processor is configured to: receive an electrical signal; determine a rate of change of the electrical signal; and modulate the broadcast frequency based at least in part on the determined rate of change of the electrical signal. In some embodiments, the RF processor is a Bluetooth processor, and the RF communications circuit is a Bluetooth processor.

[0004] In some embodiments, the Bluetooth processor is further configured to: select a broadcast signal sequence containing a predetermined number of broadcast signals; modify the broadcast signals in the sequence based on a predetermined modification algorithm; and signal the Bluetooth communication circuit to transmit the modified broadcast signal sequence to the smart device.

[0005] In one embodiment, the smart device receives the modified broadcast signal sequence and routes it to a wireless band application running on the smart device, and the wireless band application reconstructs the unmodified broadcast signal from the received modified broadcast signal based on a predetermined modification algorithm.

[0006] In some embodiments, the wireless band further includes: a coil antenna formed and / or disposed on the interconnect layer and tuned to resonate at a frequency generated by a transceiver of the smart device; and wherein the coil antenna is electrically coupled to a GPIO port of the Bluetooth processor, wherein the coil antenna is configured to receive an RF energy field generated by the transceiver and convert the RF energy into an AC signal, and transmit the AC signal to the GPIO port of the Bluetooth processor, thereby waking up the Bluetooth processor, and wherein the Bluetooth processor begins transmitting a wireless beacon including a startup sequence having a predefined power level and an identifier of the Bluetooth processor and the Bluetooth communication circuit.

[0007] In another embodiment, the wireless band further includes a first conductive plane and a second conductive plane formed on opposite edges of the wireless band and on an outer surface of the wireless band, wherein the interconnect layer is further patterned to connect the first conductive plane and the second conductive plane to terminals of a GPIO port of a Bluetooth processor, and wherein the first conductive plane and the second conductive plane contain a conductive adhesive layer.

[0008] In some embodiments, the distributor is configured to distribute wireless bands.

[0009] In another aspect, a method is disclosed. The method includes providing a polyester substrate, coating an interconnect layer on the polyester substrate and patterning the interconnect layer to electrically couple a plurality of electrical circuits, wherein the electrical circuits are formed and / or bonded on the interconnect layer and include a Bluetooth processor configured to broadcast a beacon at a broadcast frequency, a Bluetooth communication circuit, and an energy harvesting circuit, providing a photovoltaic layer coupled to the energy harvesting circuit, wherein the photovoltaic layer and the energy harvesting circuit are configured to generate an electrical signal by converting light into an electrical signal, and forming a layered battery including cathode and anode layers and a battery pouch disposed on the interconnect layer, wherein the interconnect layer includes a cathode layer, and wherein the Bluetooth processor is configured to: receive the electrical signal; determine a rate of change of the electrical signal; and modulate the broadcast frequency based at least in part on the determined rate of change of the electrical signal.

[0010] In some embodiments, the Bluetooth processor is further configured to: select a broadcast signal sequence containing a predetermined number of broadcast signals; modify the broadcast signals in the sequence based on a predetermined modification algorithm; and signal the Bluetooth communication circuit to transmit the modified broadcast signal sequence to the smart device.

[0011] In another embodiment, the smart device receives the modified broadcast signal sequence and routes it to a wireless band application running on the smart device, and the wireless band application reconstructs the unmodified broadcast signal from the received modified broadcast signal based on a predetermined modification algorithm.

[0012] In some embodiments, the method further includes: forming and / or disposing a coil antenna on the interconnect layer; tuning the coil antenna to resonate at a frequency generated by a transceiver of the smart device; and electrically coupling the coil antenna and a GPIO port of a Bluetooth processor, wherein the coil antenna is configured to receive an RF energy field generated by the transceiver and convert the RF energy into an AC signal, and transmit the AC signal to the GPIO port of the Bluetooth processor, thereby waking up the Bluetooth processor, and wherein the Bluetooth processor begins transmitting a wireless beacon including a startup sequence having a predefined power level and an identifier of the Bluetooth processor and the Bluetooth communication circuit.

[0013] In one embodiment, the Bluetooth processor further includes an ADC configured to receive a voltage from a conductive surface of the wireless band, and the Bluetooth processor is further configured to determine a rate of change of the voltage from the conductive surface, and to modulate the broadcast frequency based at least in part on the determined rate of change of the voltage from the conductive surface.

[0014] In another embodiment, the method further includes forming a first conductive plane and a second conductive plane on opposite edges of the wireless band and on an outer surface of the wireless band; and further patterning an interconnect layer to connect the first conductive plane and the second conductive plane to terminals of a GPIO port of a Bluetooth processor, and wherein the first conductive plane and the second conductive plane include a conductive adhesive layer.

[0015] In one embodiment, a wireless tracking tag includes a flexible substrate. An interconnect layer is formed on the flexible substrate and is patterned to electrically couple a plurality of electrical circuits including a wireless RF communication processor and a wireless RF communication circuit configured to generate tracking information. A battery is formed on the flexible substrate and includes a cathode layer and an anode layer, wherein a battery pouch is disposed on the interconnect layer, the battery pouch containing the electrochemical components of the battery. In some embodiments, the battery includes a cathode coating and an anode coating, wherein the battery pouch is formed on the interconnect layer, the battery pouch containing the electrochemical components of the battery to form an impermeable barrier for electrolyte chemicals to gases or moisture that are harmful to the battery life, the electrolyte chemicals including at least one member from the group consisting of ZnSO4, ZnCl2, MnSO4 and AlCl4. In some embodiments, the battery includes two electrochemical cells formed in series by a planar process, wherein there is a vertical ion flow in each electrochemical cell, wherein the planar conductive layer couples the two electrochemical cells in series. Alternatively, in some embodiments, the battery comprises two electrochemical cells formed in series by a coplanar process, wherein each electrochemical cell has lateral ion flow between an interdigitated cathode and an anode, wherein a planar conductive layer couples the two electrochemical cells in series.

[0016] In one embodiment, a wireless tracking tag tape includes a flexible substrate. An interconnect layer is formed on the flexible substrate and is patterned to electrically couple a plurality of electrical circuits including a wireless RF communication processor and a wireless RF communication circuit configured to generate tracking information. A battery formed on the flexible substrate includes a cathode layer and an anode layer, wherein a battery pouch is disposed on the interconnect layer. The battery pouch contains electrochemical components of the battery. In one embodiment, the wireless RF communication processor is a Bluetooth processor and the wireless RF communication circuit is a Bluetooth communication circuit, and the wireless RF communication processor and the wireless RF communication circuit are configured to generate a broadcast beacon at a broadcast frequency. In one embodiment, the battery is coated onto the interconnect layer. In one embodiment, the battery is a layered structure. In one embodiment, the battery is printed onto the interconnect layer. In one embodiment, the wireless RF communication processor and the wireless RF communication circuit are configured to remain in a power-saving sleep mode during storage until activated for use. In one embodiment, the wireless tracking tag tape is formed in a roll-to-roll process, wherein the wireless RF communication processor and the wireless RF communication circuit of at least one individual wireless tracking tag are activated after being separated from the roll. In one embodiment, the wireless tracking tag strap includes a coil antenna that is tuned to resonate at a wake-up frequency and generates a wake-up voltage in response to engagement with a device having a transceiver that emits a wireless signal at the wake-up frequency. In one embodiment, the wireless tracking tag strap includes a coil antenna to harvest energy from engagement with an HF RFID or NFC reader and in response generate a wake-up voltage for a wireless RF communication processor and wireless RF communication circuitry. In one embodiment of the wireless tracking tag strap, the wireless RF communication processor is configured to: receive an electrical signal; determine a rate of change of the electrical signal; and modulate a broadcast frequency based at least in part on the determined rate of change of the electrical signal.

[0017] In one embodiment, a wireless tracking tag band includes a flexible substrate. An interconnect layer is formed on the flexible substrate and is patterned to electrically couple a plurality of electrical circuits including a wireless RF communication processor and a wireless RF communication circuit configured to generate tracking information. A battery is printed onto the interconnect layer and includes a cathode layer and an anode layer. A battery pouch is disposed on the interconnect layer, the battery pouch containing the electrochemical components of the battery. The wireless tracking tag band is formed in a roll-to-roll process, wherein the wireless RF communication processor and the wireless RF communication circuit of at least one individual wireless tracking tag are activated after being separated from the roll. In one embodiment, the wireless tracking tag band includes a coil antenna that is tuned to resonate at a wake-up frequency and generates a wake-up voltage in response to engagement with a user device having a transceiver that emits a wireless signal at the wake-up frequency. In one embodiment, the wireless tracking tag band includes a coil antenna to collect energy from engagement with an n HF RFID or NFC reader, and in response generates a wake-up voltage for the wireless RF communication processor and the wireless RF communication circuit. In one embodiment, the wireless RF communication processor and the wireless RF communication circuit include a Bluetooth processor and a Bluetooth communication circuit configured to generate a broadcast beacon at a broadcast frequency.

[0018] In one embodiment, a wireless tracking tag tape has a flexible substrate. An interconnect layer formed on the flexible substrate is patterned to electrically couple a plurality of electrical circuits including an RF communication processor and an RF communication circuit configured to generate a broadcast beacon at a broadcast frequency. A battery formed on the flexible substrate has a cathode coating and an anode coating. A battery pouch is formed on the interconnect layer, the battery pouch containing the electrochemical components of the battery to form a barrier that is impermeable to gases or moisture that are harmful to the battery life. The electrolyte chemistry of the battery includes at least one member from the group consisting of ZnSO4, ZnCl2, MnSO4, and AlCl4. In one embodiment, the interconnect layer includes an aluminum layer. In one embodiment, the RF communication processor and the RF communication circuit are configured to remain in a power-saving sleep mode during storage until activated for use. In one embodiment, the wireless tracking tag tape is formed in a roll-to-roll process, wherein the RF communication processor and the RF communication circuit of at least one individual wireless tracking tag are activated after being separated from the roll. In one embodiment, the wireless tracking tag band includes a coil antenna that is tuned to resonate at a wake-up frequency and generates a wake-up voltage in response to engagement with a user device having a transceiver that emits a wireless signal at the wake-up frequency. In one embodiment, the battery includes at least two electrochemical cells formed in series by a planar process, wherein there is a vertical ion flow in each electrochemical cell, and wherein a planar conductive layer couples the two electrochemical cells in series. In one embodiment, the battery includes at least two electrochemical cells formed in series by a coplanar process, wherein each electrochemical cell has a lateral ion flow between an interdigitated cathode and an anode, and wherein a planar conductive layer couples the two electrochemical cells in series. In one embodiment, the battery includes 3 electrochemical cells connected in series using an electrical trace formed on a flexible substrate that electrically couples the top layer to the bottom layer.

[0019] In one embodiment of a method of manufacturing a wireless tracking tag band, the method includes: forming a sequence of patterned anode and cathode battery layer segments into a first segment and a second segment on a flexible substrate. The first segment and the second segment are arranged on opposite sides of a fold line. At least one conductive trace is formed that intersects the fold line between the first segment and the second segment. The method includes folding the flexible substrate along a preselected fold line to form a battery housed in a battery bag, the battery having at least 3 electrochemical cells of the battery connected in series. The method includes mounting an RF communication chip to the flexible substrate, wherein an electrical interconnect layer couples the positive current collector and the negative current collector of the battery in series to the RF communication chip, wherein the conductive trace provides an electrical connection to one of the positive current collector and the negative current collector.

[0020] In one embodiment of a method for manufacturing a wireless tracking tag band, the method includes: forming a cathode layer region and an anode layer region on a flexible substrate; patterning a transfer adhesive onto the flexible substrate in 1) a first group of regions serving as a seal; and 2) a second group of regions having an electrolyte; and applying a powdered gel electrolyte to the second group of regions. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The drawings and associated descriptions provided herein are for the purpose of illustrating specific embodiments of the present invention and are not intended to be limiting.

[0022] Figure 1A An object tracking system according to an embodiment is illustrated.

[0023] Figure 1B is a block diagram illustrating further details of a distributor and wireless band used in an object tracking system.

[0024] Figure 2A An exemplary method of dispensing wireless bands from a dispenser to track an object is illustrated.

[0025] Figure 3 Illustrated are some of the layers and arrangements of the layers in an example wireless band according to an embodiment, where a layered battery structure is used.

[0026] Figure 4 A diagram illustrating a wireless band that can pair with a smart device without using a dedicated NFC pairing chip.

[0027] Figure 5 Illustration of how to pair an NFC-enabled wireless band with Bluetooth on a smart device.

[0028] Figure 6 A diagram illustrating a communication protocol between a wireless band and a smart device that may enhance background processing of the smart device related to processing of signals received from the wireless band.

[0029] Figure 7 A method of enhancing background processing of a smart device related to receiving broadcast signals from a wireless band is illustrated.

[0030] Figure 8 An implementation of a wireless band is shown in which fluctuations in light levels can be used to modulate the frequency of a broadcast beacon.

[0031] Fig. 9 Illustrated is a method of using fluctuations in light levels to modulate the frequency of a broadcast beacon.

[0032] Fig.10 Diagram illustrating various embodiments of maintaining a wireless band in a low power state when stored or prior to deployment by a user of an object tracking system.

[0033] Fig.11A An example of a conventional battery pouch layer is shown.

[0034] Fig. 11B The functional equivalent of the battery pouch layer in providing an impermeable barrier is shown.

[0035] Fig. 11C is a side view of a battery pouch according to an embodiment.

[0036] Fig.11D is a side view illustrating how an interconnect layer forms a portion of a battery pouch according to an embodiment.

[0037] Fig.11E is a side view illustrating another example of how an interconnect layer forms a portion of a battery pouch according to an embodiment.

[0038] Fig.11F 1 is a side view illustrating an example of a battery and a battery pouch formed in a Zn and MnO2 system according to an embodiment.

[0039] Fig. 12A is a top view illustrating a coplanar battery with interdigitated cathodes and anodes according to an embodiment.

[0040] Fig. 12B is a side view of a coplanar battery and battery pouch according to an embodiment.

[0041] Fig.13 is a flow chart of a method of forming a battery pouch according to an embodiment.

[0042] Fig.14 is a flow chart of a planar manufacturing process according to an embodiment.

[0043] Fig.14A , Fig. 14B , Fig. 14C , Fig.14D and Fig.14E Graphics Fig.14 aspects of the flowchart.

[0044] Fig.15 is a flow chart of a coplanar process according to an embodiment.

[0045] Fig.15A , Fig. 15B , Fig. 15C , Fig.15D and Fig.15E Graphics Fig.15 aspects of the flowchart.

[0046] Fig.16 is a flow chart of a planar manufacturing process including folding according to an embodiment.

[0047] Fig.16AGraphics Fig.16 aspects of the process.

[0048] Fig.17 is a flow chart of a coplanar manufacturing process including folding according to an embodiment.

[0049] Fig.17A Graphics Fig.17 aspects of the process.

[0050] Fig.18A is a cross section of a battery pouch having an even number of electrochemical cells connected in series according to an embodiment.

[0051] Fig.18B FIG. 1 shows a schematic diagram of an embodiment of the present invention. Fig.18A The batteries are connected in series.

[0052] Fig. 18C 1 illustrates how a wireless tracking tag having an even number of at least four electrochemical cells connected in series may be used to power a dual voltage circuit in accordance with an embodiment.

[0053] Fig.19A The diagram shows electrochemical cells connected in series according to an embodiment.

[0054] Fig.19B Illustration of how defects or manufacturing problems in individual electrochemical cells can create excessive resistance or open connections to electrochemical cells connected in series.

[0055] Fig.19C A series-parallel arrangement is shown, wherein the electrochemical cells of the individual stages are coupled in parallel, and the stages are coupled in series.

[0056] Fig.19D Graphics Fig.19C High resistance or disconnection in individual electrochemical cells in a series-parallel arrangement.

[0057] Fig. 20A The voltage control circuit according to an embodiment is shown for switching the battery voltage of a wireless tracking tag and preventing overvoltage during the initial turn-on phase of an RF device.

[0058] Fig. 20B Graphics Fig. 20A The time response of the voltage control circuit.

[0059] Fig. 20C Graphics Fig. 20A Circuit design method.

[0060] Fig.21A A wireless tracking tag is illustrated in which discrete components of the RF circuit, such as capacitors of the RF filter, are replaced with thin film components that are compatible with the manufacture of the wireless tracking tag.

[0061] Fig.21B An example of an aluminized PET layer according to an embodiment is illustrated.

[0062] Fig. 21C An example of an RF filter circuit according to an embodiment is shown with discrete components replaced with an aluminized PET layer.

[0063] Fig.22A is a flow chart illustrating a technique for forming a via-shaped connection between conductive layers of a wireless tracking tag according to an embodiment.

[0064] Fig. 22B Illustration of forming a laser drilled hole between conductive layers of a wireless tracking tag according to an embodiment.

[0065] Fig. 22C Illustrated is a diagram of forming a mechanically created hole between conductive layers of a wireless tracking tag, according to an embodiment.

[0066] Fig.22D An example of a cross section in which a via-shaped connection is formed between conductive layers of a wireless tracking tag according to an embodiment is illustrated.

[0067] Fig.23A is a cross section of a battery structure in which an aluminum layer is protected from corrosion according to an embodiment.

[0068] Fig. 23B FIG. 4 is a partial cross-section of a battery structure according to an embodiment in which an aluminum layer is protected from corrosion.

[0069] Fig.23C In the complete structure for protecting the aluminum layer from corrosion according to the embodiment Fig. 23B Cross section of a battery structure.

[0070] Fig.23D FIG. 4 is a partial cross-section of a battery structure according to an embodiment in which an aluminum layer is protected from corrosion.

[0071] Fig.23E In the complete structure for protecting the aluminum layer from corrosion according to the embodiment Fig.23E Cross section of a battery structure.

[0072] Fig.24 is a cross-section of a variation of a battery structure having an outer aluminum layer serving as an impermeable pouch layer according to an embodiment.

[0073] Fig.25 is a cross-section of a variation of a battery structure having an outer aluminum layer serving as an impermeable pouch layer according to an embodiment.

[0074] Fig.26A An example of an interconnected spacer layer according to an embodiment is illustrated.

[0075] Fig.26B Illustrated are top and side cross-sectional views of a wireless tracking tag having interconnected spacer layers according to an embodiment.

[0076] Fig.26C and Fig.26D Illustrate how an interconnected separator may be used for bifacial cell formation in a roll-to-roll manufacturing process, according to an embodiment. DETAILED DESCRIPTION

[0077] The following detailed description of specific embodiments presents various descriptions of specific embodiments of the present invention. However, the present invention can be embodied in many different ways as defined and covered by the claims. In this description, reference is made to the accompanying drawings, in which the same reference numerals may indicate the same or functionally similar elements.

[0078] Unless otherwise defined, all terms used herein have the same meaning as those generally understood by those skilled in the art to which the present invention belongs. All patents, patent applications and publications cited throughout the disclosure herein are incorporated herein by reference in their entirety. If a term in this article has multiple definitions, the definition in that section shall prevail. Unless otherwise indicated, when the terms "one", "a" or "an" are used in this disclosure, they mean "at least one" or "one or more".

[0079] Object Tracking System 100

[0080] Figure 1A An object tracking system 100 is shown according to an embodiment. A tape dispenser 101 may be used to dispense wireless tape 102 from a roll of rolled wireless tape 102. Dispenser 101 may include a cutting device 115 for removing wireless tape 102 from its roll. Wireless tape 102 may include an adhesive layer that allows it to be attached to various objects for tracking.

[0081] The wireless band 102 is capable of wireless communication with a smart device 103. The smart device 103 may be any kind of computer system capable of sending and receiving wireless communications to and from the wireless band 102. Examples include smart phones, tablets, smart glasses, smart watches, laptops, desktops, personal digital assistant (PDA) devices, etc. In one embodiment, a wireless band application 121 may be run on the smart device 103 to manage the operation of one or more wireless bands 102. The wireless band application 121 may include program instructions to wirelessly communicate with the wireless band 102 and the server 104 via a wired or wireless connection to a network 150. The network 150 may be a local area network, an intranet, a wide area network, the Internet, the Internet, a wireless network, a wired network, Wi-Fi, Bluetooth, a cellular network, or other network. The server 104 may be local to the wireless band 102 and / or the smart device 103, or it may be at a remote location.

[0082] The wireless band application 121 may maintain and / or manage a local database 120 on the smart device 103. The local database 120 may store various information related to the tracking and management of the wireless bands 102, such as an identifier for each wireless band 102, the name of the associated item to which the wireless band is attached, a description and / or image of the item, historical tracking data, an identifier of the owner / custodian of the item, and other information related to the tracked object that may be desired to be stored. The data stored in the local database 120 may be stored in addition, instead, or in part in a remote database 122 at the server 104. The server 104 may include a remote database 122 that includes information about additional wireless bands 102 that may be associated with the user and other users of the wireless bands 102. Although illustrated as a single server 104, the server 104 may be implemented as multiple networked servers.

[0083] Figure 1B1 is a block diagram illustrating more details of the dispenser 101 and the wireless band 102. The dispenser 101 may include a beacon 110 including a wireless communication system and a cutting device 115 for removing a sheet of the wireless band 102 from its reel. The beacon 110 may be any wireless communication device capable of transmitting wireless communication signals to and receiving wireless communication signals from the smart device 103. As previously described, the dispenser 101 may include a cutting device 115 configured to remove the wireless band 102 during the dispensing process. In other embodiments, the dispenser 101 may be a housing that encloses a stack of wireless bands 102 folded on top of each other in a zigzag pattern. A small slit in the housing allows at least one wireless band 102 to extend through the slit, enabling a user to tear off a wireless band 102 from the rest of the stack. The wireless band 102 may be separated by a perforation, along which a user may tear off a wireless band 102 and separate it from the rest of the wireless bands. Instead of or in addition to perforations, cutting means at the slits may facilitate separation of the wireless band 102 from the rest of the wireless bands.

[0084] The wireless band 102 may include multiple electronic devices on a flexible and ultra-thin substrate 116. In some embodiments, the electronic devices in the wireless band 102 may include wireless communication circuitry 111, a processor 112, a timer 113, a battery 114, and a memory module 117, which are etched, manufactured, bonded, or otherwise formed on the substrate 116 and connected by an interconnect layer 118. The interconnect layer 118 may be any conductive material including aluminum, copper, gold, silver, etc. Although the circuit system in the wireless band 102 is shown as a discrete component, it can be understood by a person of ordinary skill in the art that these components can be combined in a single or multiple chips according to various embodiments of the disclosed embodiments. For example, when the wireless band 102 is implemented using Bluetooth wireless communication circuitry, the processor 112 may include the Bluetooth wireless communication circuit system and the timing circuit as well as volatile and non-volatile memory to perform the operation of the wireless band 102. Alternatively, some components may be integrated, while other components may remain as separate components.

[0085] Using the Object Tracking System 100

[0086] Figure 2AAn exemplary method 200 of dispensing a wireless band 102 from a dispenser 101 to track an object is illustrated. The wireless band 102 may be dispensed from a roll of wireless band 102 and subsequently attached to an item to be tracked. In step 201, in a single action, the wireless band 102 is dispensed from the dispenser 101 and activated simultaneously. Activation may refer to waking up the processor 112 to send / receive wireless signals, beacons, packets, or other wireless messages using the wireless communication circuit 111. In step 202, the wireless band 102 may transmit a wireless signal to the smart device 103. The wireless signal may be transmitted at predetermined intervals based on a signal from a timer 113, or may be transmitted based on a detected environmental change (such as by electrostatic detection or other mechanisms, such as ambient light sensing, accelerometers, or other methods), as described herein.

[0087] The wireless signal transmitted from the wireless band 102 may include a unique identifier encoded in the memory module 117 of the processor 112, wherein the identifier is unique among all wireless band devices. In step 203, the smart device 103 may receive the wireless signal from the wireless band 102. In step 204, configuration and setup of the wireless band 102 may be performed on the smart device 103. The configuration and setup of the wireless band 102 may include registering the item to be tracked and associating the item with the unique identifier of the wireless band 102, and recording the registration and association in one or more local or remote databases including the local database 120 and the remote database 122. The smart device 103 may check the identifier in the local database 120. If the identifier is located in the local database 120, the smart device 103 may display some or all stored information about the wireless band device and its associated item. Otherwise, the smart device 103 may transmit a request to the server 104 to query the remote database 122 using the identifier. If the identifier is found in the remote database 122, information about the wireless band device is retrieved from the remote database 122 and transmitted from the server 104 to the smart device 103, which can display the information. For example, the smart device 103 can display an indication of the owner of the wireless band 102. Otherwise, if the wireless band 102 is not found in both the local database 120 and the remote database 122, this can indicate that the wireless band 102 is not associated with any smart device 103 and can be paired with the smart device 103. The smart device 103 can prompt the user to pair the wireless band 102, thereby claiming its ownership. The smart device 103 can display a user interface element on its screen for inputting information about the item to which the wireless band 102 is attached and / or to be tracked. The smart device 103 can collect information, such as the name and description of the item. The collected item information can include text input, photos of the item, videos, voice memos, and / or any other data associated with the item and / or the owner / tracker of the item. The collected item and / or owner data may be stored in the local database 120 and / or the remote database 122 along with the identifier of the paired wireless band 102 .

[0088] Wireless Band 102

[0089] The various techniques and materials described herein can be used to manufacture the wireless band 102 in an ultra-thin manner. For example, including a battery source in most ultra-thin devices can be challenging. In one embodiment, the wireless band 102 can be manufactured as a laminate structure, wherein the battery source is integrated into the laminate structure to distribute the battery components between the layers, thereby reducing the total area consumed by the battery source and maintaining the flexibility of the wireless band 102.

[0090] Figure 3The diagram illustrates the arrangement of some layers and layers in an example wireless band 102 according to an embodiment, wherein a layered battery structure is used. In the illustrated embodiment, the anode layer 302 of the battery that powers the wireless band 102 is the bottom layer. In one embodiment, the anode layer 302 can be a graphite-coated anode in a roll-to-roll process. The substrate layer 116 and the components thereon are sandwiched between the anode layer 302 and the photovoltaic layer 310. The photovoltaic layer 310 can be formed by a lattice of an organic photovoltaic (OPV) material or other solar energy collection material. The interconnect layer 118 formed on the substrate 116 can be used as the cathode of the battery that powers the electronic device 306 of the wireless band 102. A battery bag 308 containing the electrochemical components of the battery can be formed on the interconnect 118. The substrate 116 can be an ultra-thin and flexible material, such as polyester or polyethylene terephthalate (PET). The interconnect layer 118 can be coated with a conductive metal, such as aluminum. The battery bag 308 can be manufactured by coating the interconnect 118 in the battery portion with an active lithium compound (such as lithium manganese dioxide). The wireless band 102 may also include an adhesive layer 304 to allow the wireless band 102 to be attached to an item for tracking or other purposes.

[0091] Depending on the implementation of the wireless band 102, the electronic device 306 may include various components. For example, if the photovoltaic layer 310 is used, the electronic device 306 may include a circuit system that collects and utilizes the light energy absorbed from the layer to power the electronic device 306. If a manual beacon trigger feature is included, the electronic device 306 may include an associated switch and / or piezoelectric sensor. The electronic device 306 may include components of the wireless band 102 as described above. Examples include wireless communication circuitry 111, processor 112, timer 113, and memory 117. These components may be discrete, separate components, or they may be part of an integrated circuit that implements their functions in one or more chips. In some embodiments, as will be described, the electronic device 306 may include an analog-to-digital converter (ADC). Depending on the implementation of the wireless band 102, additional electrical components 306 may include a near field communication chip (NFC), sensors (e.g., sensors for detecting ambient light, motion, acceleration, temperature, etc.). Although not shown, the interconnect layer 118 may be patterned in a manner that provides electrical connection and / or isolation between the electrical components 306 of the wireless strip 102. The layers shown are for example purposes only, and one of ordinary skill in the art will appreciate that the wireless strip 102 may be manufactured using more or fewer layers than shown.

[0092] Example Dimensions and Components of Wireless Band 102

[0093] Embodiments of the wireless band 102 can be constructed in a variety of ways. One embodiment of the wireless band 102 is a paper-thin label that contains ultra-thin electronics printed or etched on a laminate layer of a polyester film (e.g., PET), as previously described. In some embodiments, the thickness of the wireless band 102 (including the layers and electronics therein) can be in the range of about 1 / 20 of a millimeter to half a millimeter, depending on the embodiment. Depending on the embodiment, the electronics 306 can be etched or printed into the interconnect layer 118, or they can be attached or otherwise bonded to the interconnect layer 118, as separate chips or circuits or as various integrated or separate components.

[0094] To help achieve an ultra-thin form factor for the wireless band 102, one or more of the surface areas of the battery pouch 308, the anode layer 302, or the cathode layer (e.g., some or a portion of the interconnect layer 118) can be used as a wireless communication antenna, replacing a conventional dedicated antenna component (such as a printed antenna). For example, in some embodiments, the surface area of ​​the battery pouch 308 encompasses a significant area within the wireless band 102 and can additionally act as a wireless antenna component for a radiating wireless beacon. When a Nordic nRF52810 or similar processor 112 is used, a wireless balanced-unbalanced transformer (balun) at the analog output of the processor 112 can be connected to the outer metal foil of the battery pouch 308, or the anode layer 302, or to the interconnect layer 118 and / or a portion thereof, where these components can additionally act as antennas.

[0095] The wireless band 102 can be designed with an adhesive layer to attach the wireless band 102 to the surface of an item of interest to track the item. In one embodiment, as described, in some embodiments, the wireless band 102 can be manufactured on a very flexible substrate 116 (e.g., a PET substrate) with a thin flexible battery source printed or laminated directly onto a flexible coated interconnect layer 118 therein. In one embodiment, the battery can be printed onto the interconnect layer 118.

[0096] In one embodiment, the wireless band 102 can be designed to adhere to a range of surfaces and things. In one embodiment, one or both sides of the wireless band 102 are coated with an adhesive to allow attachment to other objects.

[0097] Method for pairing the wireless band 102 with the smart device 103

[0098] In one embodiment, the wireless communication circuit 111 may be activated and paired with the smart device 103 using near field communication (NFC).

[0099] NFC can be used to pair NFC-enabled Bluetooth devices (such as Internet of Things (IOT) devices, wearable devices, or other devices) with user accounts on mobile phones. The pairing process can also pair these devices with a back-end database associated with a user account. This works by the user touching or bringing their smart device (e.g., smart phone) close to the NFC-enabled Bluetooth device. The coil antenna on the circuit board inside the NFC-enabled Bluetooth device receives the RF energy field of the user's smart device and converts it into an electrical signal that can turn on the NFC chip inside the NFC-enabled Bluetooth device. Example NFC chips include NTAG213, NTAG214, and NTAG215 manufactured by NXP Semiconductors NV of Eindhoven, Netherlands (https: / / www.nxp.com / ). Using the same energy collected by the coil, the NFC chip can return the NFC unique identifier to the user's smart device. This NFC unique identifier is linked to the Bluetooth identifier of the NFC-enabled Bluetooth device via back-end software (e.g., a database) (e.g., when this product is manufactured). The user's smart device can use the Bluetooth identifier to pair with the NFC-enabled Bluetooth device and communicate with it via Bluetooth. The pairing information can also be used to associate the NFC-enabled Bluetooth device with the user's profile and account in the backend database.

[0100] The NFC pairing method described above can be used to pair the wireless band 102 with the user's smart device 103, thereby eliminating the need for continuous broadcasting of wireless beacons for pairing. Compared to the continuous broadcasting method for pairing, the NFC method of pairing the wireless band 102 with the smart device 103 does not consume battery power and extends the life of the wireless band 102. Additionally, the described NFC pairing technology can prevent multiple users from pairing with the same wireless band 102 at the same time, because only users whose smart devices 103 remain close to the NFC-enabled wireless band 102 (e.g., within 2-3 cm of the wireless band 102) can receive the NFC unique identifier and pair with this wireless band 102.

[0101] However, in some embodiments, including an NFC chip (such as NTAG213) may increase the manufacturing cost of the wireless band 102, and / or the chip area dedicated to the circuit system for pairing. Therefore, it is advantageous to pair the wireless band 102 with the smart device 103 using NFC technology without using a dedicated NFC chip for pairing.

[0102] Figure 4A graphic 400 of a wireless band 102 is shown, which can be paired with a smart device 103 without using a dedicated NFC pairing chip. As previously described, the electronics of the wireless band 102 can be manufactured on an interconnect layer 118, which is patterned to create electrical connections and isolation between various electrical components on the interconnect layer 118. The graphic 400 does not illustrate every component and layer of the wireless band 102 that supports NFC. Only some components are shown to illustrate Bluetooth pairing using NFC without using a dedicated NFC chip. The NFC coil antenna 402 and the RF energy harvesting circuit 404 can be manufactured on the interconnect layer 118. The user's smart device 103 is equipped with an NFC transceiver 406, which is capable of generating and transmitting an RF energy field with a wake-up frequency (WUF). The coil antenna 402 is tuned to resonate at the wake-up frequency WUF sent by the transceiver 406. In some embodiments, the NFC energy harvesting circuit 404 may include components, such as one or more capacitors and rectifiers, to convert an alternating current (AC) signal generated in the coil antenna 402 into a direct current (DC) signal, by which the processor 112 can be awakened. In another embodiment, the NFC energy harvesting circuit 404 may include a component that captures a wake-up voltage 408 from the coil antenna 402 and transmits the wake-up voltage 408 to the processor 112 to wake up the processor 112. In another embodiment, the NFC energy harvesting circuit 404 and some or all of its components may be skipped. In this case, the wake-up AC voltage generated in the coil antenna 402 may be used to directly wake up the processor 112 without converting the AC voltage to a DC voltage. The advantages of eliminating some or all of the components of the NFC energy harvesting circuit 404 include reducing the manufacturing cost and complexity of the NFC-enabled wireless band 102. In other embodiments, when the processor 112 is implemented as a system-on-chip (SOC) solution, some or all of the components of the NFC energy harvesting circuit 404 may be integrated into the processor 112.

[0103] Figure 5The method 500 of Bluetooth pairing of the wireless band 102 supporting NFC and the smart device 103 is illustrated. As described above, the processor 112 can be a Bluetooth microprocessor, such as the nRF52810 of Nordic Semiconductor, and the wireless communication circuit 111 can be a Bluetooth communication circuit. Although the processor 112 and the wireless communication circuit 111 are shown as separate components, in some embodiments, they can be part of an integrated Bluetooth chip. The processor 112 includes a general purpose input / output (GPIO) port capable of receiving GPIO signals. The smart device 103 can be configured to execute program instructions to run the wireless band application 121. The wireless band application 121 can configure the transceiver 406 to resonate at a wake-up frequency WUF. The method 500 starts at step 502. At step 504, the user of the smart device 103 executes the wireless band application 121 and brings the smart device 103 close to the coil antenna 402 of the wireless band 102 (e.g., within approximately 5 cm). At step 506, the transceiver 406 generates and transmits an RF energy field at a wake-up frequency WUF. The coil antenna 402 is tuned to resonate at the wake-up frequency WUF. At step 508, the coil antenna 402 resonates at the wake-up frequency WUF and generates and transmits a wake-up voltage 408 to the GPIO port of the processor 112.

[0104] In some embodiments, the NFC energy harvesting circuit 404 may include a component that converts the wake-up AC voltage 408 to a DC voltage. However, both DC or AC voltages may be used at the GPIO port of the processor 112 to wake up the processor 112. For example, in some embodiments, a voltage (DC or AC) above 0.7 volts (V) at the GPIO port may wake up the processor 112. In some cases, it may be desirable to convert the wake-up AC voltage 408 to a DC voltage to protect the processor 112 from potentially receiving unsafe high voltages. Nevertheless, in some embodiments, the AC to DC conversion may be safely skipped because the voltage range encountered by the NFC-enabled wireless band 102 and the coil antenna 402 is likely to not exceed a level that may be unsafe for the processor 112. As a result, the wake-up AC voltage 408 generated in the coil antenna 402 may be applied to the GPIO port of the processor 112 without the need for conversion. In this case, the NFC-enabled wireless band 102 may be manufactured without the need for components, cost, and complexity of converting NFC voltages.

[0105] In embodiments where the threshold voltage for waking up the processor 112 is higher than the voltage range that the coil antenna 402 can generate, as part of a system-on-chip (SOC) solution, a comparator circuit that is an external component or an integrated component in the processor 112 can receive the wake-up signal and wake up one or more additional circuits in the processor 112. Further, in some embodiments, the processor 112 can wake up when it receives a voltage higher than the wake-up threshold voltage of about 0.7V, where the antenna coil 402 can generate a voltage of about 0.3-0.4V or less. The comparator circuit can detect the low voltage generated from the antenna coil 402 (e.g., as low as about 1.8V in some embodiments) and wake up the remaining circuitry in the processor 112.

[0106] At step 512, the processor 112 receives the wake-up voltage 408 at its GPIO port and wakes up from an inactive state (e.g., a deep shutdown state). At step 514, the processor 112 uses the wireless communication circuit 111 to send a sequence of Bluetooth beacons 412 (e.g., via a low-power BLE signal), which can be received by the wireless communication facilities of the smart device 103. The wireless facilities of the smart device 103 may include a Bluetooth communication circuit 414. The Bluetooth beacon 412 may include a Bluetooth identifier and / or other information that may be included in the pairing process. For example, the Bluetooth beacon 412 may include a unique identifier of the wireless band 102. At step 516, the wireless band application 121 may receive the information embedded in the Bluetooth beacon 412 and use them to associate the wireless band 102 with the wireless band application 121 and the user profile of the smart device 103. The method 500 ends at step 518.

[0107] In some embodiments, the Bluetooth beacon 412 can be customized to further identify the wireless band 102 and / or other information to be included in the pairing process. For example, the Bluetooth beacon 412 can include an initial startup sequence having a predefined sequence and / or having a predefined power level, which is also identified and recorded in the wireless band application 121. Such information can be uploaded via the wireless band application 121 after purchasing a roll of wireless application band 102, the dispenser 101, and stored in the local database 120 and / or the remote database 122. In some embodiments, the camera of the smart device 103 can be used to scan a barcode from the dispenser 101 or from a roll of wireless band 102, wherein the barcode can include pairing information associated with the wireless band 102.

[0108] Although method 500 is described in the context of pairing Bluetooth devices, it will be appreciated by those skilled in the art that the system and method may be modified to apply to other communication protocols, such as radio frequency identification (RFID), etc. Additionally, although the system and method of NFC pairing without a dedicated NFC chip are described in the context of pairing of wireless band 102, it will be appreciated by those skilled in the art that the technology may be used in other applications where pairing of wireless devices is desired. For example, in many applications, wireless device pairing is performed infrequently or only once in the life of the product. At the same time, the cost of an NFC chip used infrequently or only once for initial pairing may be too high in some applications. The technology may be used in these and other scenarios where wireless device pairing is desired.

[0109] Figure 6 A diagram illustrating a communication protocol between a wireless band 102 and a smart device 103 that can enhance background processing of the smart device 103 related to processing of signals received from the wireless band 102. In one embodiment, the wireless band 102 can modify its broadcast signals 602 to simulate multiple devices transmitting them. The operating systems of the smart device 103 and similar devices are more likely to listen to the received broadcast signal and allocate more background processing to it if the received broadcast signal 602 appears to be from a new device that they have not previously listened to and / or have not previously processed. In other words, in the described embodiment, the broadcast signal 602 is not redundant. The redundancy in the broadcast signal 602 can be removed in a variety of ways.

[0110] Figure 7A method 700 is illustrated for enhancing background processing of a smart device 103 associated with receiving broadcast signals 602 from a wireless band 102. The method 700 begins at step 702. At step 704, a sequence of broadcast signals 602 is selected that includes a predetermined number of broadcast signals 602. In one embodiment, the broadcast signals 602 are packets in a BLE beacon format. At step 706, the broadcast signals 602 in the sequence are modified according to the PMA. In some embodiments, the PMA modifies a MAC address and / or UUID embedded in one or more broadcast signals 602. At step 708, the wireless band 102 transmits the modified sequence of broadcast signals 602 to the smart device 103. At step 710, the smart device 103 may receive the modified broadcast signals 602 and route them to the wireless band application 121. The smart device 103 is more likely to receive some or all of the transmitted sequence of modified broadcast signals 602 because they appear to be from different sources. At step 712, wireless band application 121 may receive the sequence of modified broadcast signals 602 and determine locally and / or in combination with server 104 and based on PMA that the modified broadcast signal 602 is from wireless band 102. For example, in some embodiments, wireless band application 121 and / or server 104 may apply a PMA-based reconstruction algorithm to reconstruct the original MAC address and / or UUID of the received modified broadcast signal 602. Method 700 ends at step 714.

[0111] Method for achieving ultra-low power using changing ambient light levels to trigger power saving states in microprocessor-based devices

[0112] For many wireless devices (e.g., IOT devices), saving battery power may be crucial. In order to maintain an ultra-thin profile, many devices use a main power supply. When the battery is exhausted, the battery or the device must be replaced. In many applications, it is usually the device that must be replaced because changing the used battery is not a viable option. As a result, many modern wireless devices need to save batteries to achieve a longer product life. Nevertheless, many wireless devices broadcast their beacons periodically, regardless of whether the listening device can capture their beacons. This situation poses a challenge to applications where the broadcasting device has limited battery resources. For example, when the smart device 103 is nearby and can receive the beacon and communicate with the wireless band 102, it is advantageous for the ultra-thin profile wireless band 102 for tracking items to broadcast its beacon. It is also advantageous for the wireless band 102 to limit or stop sending broadcast beacons when there is no smart device 103 nearby to receive the beacon. Additionally, if the smart device 103 is nearby and can receive and process these beacons, it is desirable to increase the frequency of the wireless band 102 broadcasting its beacon. Conversely, if there are no smart devices 103 nearby to receive the beacons, it may be advantageous to reduce the frequency of sending beacons (or stop sending).

[0113] Sensors can be used to modulate the broadcast of beacons and / or their transmission frequency in order to save battery resources. For example, vibration or motion sensors can be used in wireless devices (such as wireless band 102) to trigger and / or modulate the transmission frequency of broadcast beacons emitted from the wireless device. If the sensor detects motion and / or vibration, the wireless device can increase the frequency of sending broadcast beacons. However, in some applications, sensors consume more battery resources than they save. For example, in some applications, motion sensing using passive infrared (PIR) or similar motion sensors and motion sensing using accelerometers to save battery resources can consume more battery resources than they save battery resources. However, in other applications, the cost of additional sensors may be too high relative to the overall target cost of the product, thereby making the use of these sensors impractical. For other wireless devices, the form factor and size of these sensors may be incompatible with their form factor or design.

[0114] In the case of wireless devices operating via NFC, solar or other energy harvesting methods, battery resources may be limited. Therefore, it is advantageous to reduce or minimize broadcast beacons when there are no listening smart devices 103 nearby.

[0115] In one embodiment, fluctuations in the light level in the environment of the wireless device can be used to modulate the frequency of the broadcast beacon. In this case, fluctuations in the light level in the environment can indicate the presence of the listening smart device 103. For example, when a wireless device (such as a wireless band 102) is used for asset tracking, the wireless band 102 can be attached to an item that is placed in a delivery van, a work truck, a supply room, or other physical location where the item and the attached wireless band 102 are stored. When a person carrying a smart device 103 interested in the tracked item enters the physical location where the item and the attached wireless band 102 are located, the environment may experience fluctuations in light levels. For example, when a person enters the environment, an automatic motion sensor in the environment can turn on the lights. Or when a person opens a door to a storage area (such as a cargo compartment of a van or truck), the storage area where the tracked item and the wireless band 102 are located can be exposed to external light and experience fluctuations in light levels.

[0116] Figure 8 An embodiment of the wireless band 102 is shown in which fluctuations in light levels can be used to modulate the frequency of a broadcast beacon. In this case, the wireless band 102 includes a photovoltaic layer 310 (e.g., in combination with Figure 3As the photovoltaic layer 310 is exposed to various light sources 804, fluctuations in light levels may occur. The photovoltaic layer 310 and the energy collection circuit 802 convert light into an electrical signal 804 (e.g., a voltage or current) that can be received by the processor 112. The processor 112 can modulate the frequency of the beacon sent from the wireless communication circuit 111 based on the value of the electrical signal 804. For example, the processor 112 can increase the frequency of the broadcast beacon based on the rate of increase of the voltage received in the electrical signal 804. Therefore, when a person carrying a smart device 103 enters the environment of the wireless band 102 and exposes the photovoltaic layer 310 to fluctuations in light levels, the voltage generated by the energy collection circuit 802 can increase at a rapid rate R1. The processor 112 can correspondingly increase the rate of broadcast beacons from the wireless communication circuit 111 at rate R1 or increase it to an increased rate based on R1. In this way, the increased broadcast beacons have a better chance of being detected by the smart device 103.

[0117] Conversely, if the light fluctuations in the environment of the photovoltaic layer 310 are minimal, the voltage / current of the electrical signal 804 does not change or changes at a reduced rate R2. The processor 112 can adjust the frequency of broadcast beacons from the wireless communication circuit 111 to the reduced rate R2 or another reduced rate based on R2. If R2 is zero, the frequency of broadcast beacons can also be zero or a reduced amount (e.g., every thirty seconds) to save battery energy. In some embodiments, the electrical signal 804 can be used to wake up the processor 112 and start broadcasting beacons.

[0118] Fig. 9 A method 900 is illustrated for modulating the frequency of a broadcast beacon using fluctuations in light levels. The method 900 begins at step 902. At step 904, the photovoltaic layer 310 and the energy collection circuit 802 generate electrical signals by converting light energy from various light sources 804. At step 906, the processor 112 receives the electrical signal 804 and determines a rate of change of the electrical signal 804 based on the fluctuations in the converted light energy. At step 908, the processor 112 modulates the frequency of a broadcast beacon sent from the wireless communication circuit 111 based on the determined rate. The method 900 ends at step 910.

[0119] Additional Methods of Activating Wireless Band 102

[0120] It may be advantageous to conserve battery resources of the wireless band 102 by maintaining the electronics 306 in a low-power, off state until the wireless band 102 is to be used. Fig.10Diagrams illustrating various embodiments of maintaining the wireless band 102 in a low power state when stored or prior to deployment by a user of the object tracking system 100. In one embodiment, two conductive planes 1002 and 1004 may be patterned on the interconnect layer 118 or in one or more layers of the wireless band 102 such that the conductive planes 1002 and 1004 form part of an edge 1006 of the wireless band 102. The edge 1006 may be the edge between two discrete wireless bands 102 (e.g., from a roll of wireless band 102). The metal cutting device 115 may shear the roll of wireless band 102 and separate them at the edge 1006. The same process may be utilized to activate / wake up the processor 112 and / or other electronics of the wireless band 102. The interconnect layer 118 is patterned to electrically connect the conductive plane 1002 to the GPIO port of the processor 112 and to electrically connect the conductive plane 1004 to the battery 114. For ease of illustration, the battery 114 is shown as a single component on the interconnect layer 118. However, as previously described with respect to Figure 3 As described, the battery 114 may be a layered structure on multiple layers of the wireless band 102. The cutting device 115 may be made of a metal material, which may electrically connect the conductive planes 1002 and 1004 during the shearing edge 1006, thereby generating a signal from the battery 114 at the GPIO port of the processor 112. The signal at the GPIO port of the processor 112 may wake up and activate the processor 112. The processor 112 may send a beacon to a nearby smart device 103 for connection and communication.

[0121] In another embodiment, the conductive planes 1002 and 1004 may be patterned on the same surface of the interconnect 118 and on opposite edges 1014 and 1016 of the wireless strip 102, respectively. The conductive planes 1002 and 1004 may be electrically connected to the conductive planes 1008, 1010, respectively. The conductive planes 1008 and 1010 are formed on the outer surface 1018 of the wireless strip 102 on opposite edges 1014 and 1016 of the wireless strip 102, respectively, from conductive and adhesive materials. The conductive planes 1002 and 1004 and the conductive planes 1008 and 1010 are electrically coupled to the terminals of the GPIO port 1012 of the processor 112 via the interconnect pattern in the interconnect layer 118. In this arrangement, the conductive planes 1002, 1004, 1008, and 1010 form a disconnect switch between the terminals of the GPIO port 1012. When the user of the wireless band 102 intends to activate the wireless band 102, he can bring the opposite edges 1014 and 1016 of the wireless band 102 together and adhere the conductive planes 1008 and 1010 together. Connecting the conductive planes 1008 and 1010 closes the switch and connects the terminals of the GPIO port 1012, generating a signal in the processor 112 and causing the processor 112 to wake up and start transmitting beacons for connection and communication. In another embodiment, the conductive planes 1008 and 1010 from the outer surface 1018 of the wireless band 102 can be routed to the terminals of the GPIO port 1012 directly or via an interconnect pattern in the interconnect layer 118. In this case, the conductive planes 1002 and 1004 on the interconnect layer 118 can be excluded and not manufactured.

[0122] Some examples of roll-to-roll manufacturing processes and manufacturing considerations will now be described. In some embodiments, wireless band 102 is manufactured to include a series of wireless tracking tags, each of which may include wireless communication circuitry 111, processor 112, timer 113, battery 114, and memory module 117.

[0123] The manufacturing roll of wireless tape 102 formed on the flexible substrate 116 includes many individual wireless tracking tags. This leads to several problems. First, a roll of wireless tape can be stored for a period of time before it is cut into different individual wireless tracking tags. The individual tracking tags may not necessarily be used immediately when cut. However, as discussed above, the (one or more) processors and (one or more) communication circuits can be activated as needed. That is, at a time close to when the individual tracking tags are to be used, the individual wireless tracking tags can be awakened from a dormant or sleep state. This can include activating the wireless tracking tag in response to cutting the wireless tracking tag from the roll. It can also include a wireless tracking tag that wakes up in response to receiving energy from an external device. As discussed above, the coil on the wireless tracking tag can receive energy from an NFC reader or other source for generating a wake-up voltage.

[0124] In the context of wireless tracking tags, in some end-use applications, the wireless tracking tags may only need to be activated for less than a month to support, for example, tracking of package shipments in a supply chain.

[0125] Keeping individual wireless tracking tags in sleep mode until close to the time of using them prolongs the life of the battery 114. For example, this supports the option of omitting the use of solar cells to collect energy.

[0126] In a roll-to-roll manufacturing process, it is desirable to design layers that optimize multiple objectives. First, while the underlying substrate is flexible, it is desirable to minimize the number of unnecessary layers and the number of critical alignments in the manufacturing process. It is also desirable that the entire manufacturing process minimize the likelihood of defects (e.g., pinholes or other sealing defects) that would increase the permeability of the battery pouch 308 to water vapor, oxygen, or other harmful gases that could potentially shorten the life of the battery. In addition, depending on the electrolyte chemistry used, preventing harmful evaporation of the electrolyte may also be a consideration when designing the battery pouch.

[0127] The life of the battery will depend, at least in part, on the quality of the battery pouch 308 as a barrier to water vapor, oxygen, or other harmful gases. The battery pouch 308 also acts as a barrier to prevent evaporation of the electrolyte.

[0128] Depending on the end-use application, in some cases, the wireless tracking tag may only require a battery 114 and a battery pouch 308 designed to be sufficient to allow the battery 114 to last in a dormant state for some initial period of time before use, and to provide sufficient power for a typical wireless tracking application after activation. For example, in many shipping applications, the total shipping time may be less than a month when all the different legs of the shipping process are taken into account.

[0129] The electrochemical components of the battery 114 may include an electrolyte chemistry that includes at least one member from the group consisting of ZnSO4, ZnCl2, MnSO4, AlCl4. These types of electrolyte chemistries are safer and more environmentally friendly than some alternatives such as lithium cell batteries. The advantages of lithium-based cells have a nominal voltage of 3.0 or 3.6V and up to 4.2V when fully charged. In contrast, many other electrochemical cells have a much lower nominal voltage, such as approximately 1.5V in many cases. However, many communication and processor chips are designed to operate within a voltage range higher than 3.0V. In fact, due to the widespread use of lithium batteries, many communication and processor chips are designed to operate within the typical voltage range of lithium batteries.

[0130] This means that a direct replacement for a lithium cell type battery (without using a voltage multiplier chip or a dedicated low voltage chip designed to operate at lower voltages) requires connecting several 1.5V electrochemical cells in series.

[0131] It will be appreciated that the battery 114 includes cathode and anode current collectors, a separator and an electrolyte. The current collectors may be based, for example, on a carbon layer or a carbon-coated aluminum interconnect layer.

[0132] As previously discussed, a battery pouch 308 containing the electrochemical components of the battery 114 may be formed on the interconnect 118. The substrate 116 may be an ultra-thin and flexible material such as polyester or polyethylene terephthalate (PET), although other materials may also be used.

[0133] One aspect that should be understood is that the battery pouch 308 is designed to provide an impermeable barrier to harmful water vapor and harmful gases (such as oxygen). The battery pouch 308 is also designed to prevent the electrochemical components of the battery from evaporating.

[0134] In some embodiments, the battery pouch has multiple layers of film to protect the battery. Fig.11A As illustrated, the battery pouch may be formed from a multi-layer film that may include a polypropylene (PP) composite layer, an aluminum layer (Al), a biaxially oriented nylon layer (ONY), a PET layer, and other optional layers.

[0135] But if Fig. 11B As illustrated, the battery pouch may be formed from other sequences of layers that provide the functionality of acting as a barrier to water vapor and harmful gases and preventing evaporation of electrochemical components.

[0136] refer to Fig. 11C The battery pouch 308 is formed by forming at least one side of the battery pouch 308 using one or more interconnect layers 118A, 118B. The bottom interconnect layer 118A is formed on the flexible substrate 116. Fig. 11C , the bottom interconnect layer 118A forms the bottom side of the battery pouch 308. In some embodiments, the top interconnect layer 118B can also be used to form the top side of the battery pouch 308. As an example, some types of interconnect layers (such as aluminum) are impermeable to harmful gases. The entire battery pouch 308 includes a barrier layer to form a barrier for the battery 114, which in this example includes two electrochemical cells 1105 with a series electrical connection 1110. As indicated by the dotted line, the series connection 1110 can be formed between at least two electrochemical cells 1105. This is useful in cases where the individual electrochemical cells (such as electrochemical cells with electrolytes such as ZnSO4, ZnCl2, MnSO4, or AlCl4) produce a voltage of approximately 1.5V.

[0137] refer to Fig.11D , one or more interconnect layers (such as bottom interconnect layer 118A and top interconnect layer 118B) can be used to form at least a portion of the top and bottom sides of a battery pouch 308 having an interior region 1120 to accommodate electrochemical components ( Fig.11D An additional seal 1105 may be formed to complete the battery pouch 308 .

[0138] refer to Fig.11E In some embodiments, the seal region is formed by a transfer adhesive 1115. The transfer adhesive 1115 used to form the seal region can be selected to be electrically insulating. Many variations of interconnect layer designs and current collector layers 1130 are possible to form a series electrical connection between at least two electrochemical cells.

[0139] refer to Fig.11F As an illustrative but non-limiting example, the bottom interconnect layer 118A can be formed of an aluminum layer formed on a flexible PE substrate. The anode can be formed of Zn, and the cathode can be formed of MnO2. Each electrochemical cell can include a separator with an electrolyte, such as cellulose. A variety of different manufacturing processes can be used to support current collection and electrical series connection between electrochemical cells. This can include a carbon layer as an option.

[0140] In some embodiments, the cell structure 1205 is coplanar in that it is formed using interdigitated cathodes 1210 and anodes 1215 with lateral ion flow. Fig. 12A Top view of a coplanar design (not to scale). Fig. 12B 1 is a side view of the alternating cathode region 1210 and anode region 1215. In a coplanar design, there is a lateral ion flow between laterally adjacent interdigitated anode and cathode regions. This can be contrasted with a planar design, in which the ion flow is vertical relative to the cathode and anode layers in the same vertical stack.

[0141] Although the bottom interconnect layer 118A and / or the top interconnect layer 118B can be used to form a portion of the battery pouch 308, a variety of other materials can also be used to form a portion of the battery pouch. A variety of materials can be used to form a portion of the battery pouch, including thermochromic paper, resin coated facestock, etc. A variety of materials are good barriers in themselves, or can be made impermeable by, for example, adding resins, waxes, or various sol-gel processes and coatings. In one embodiment, a transfer adhesive is used to form an edge seal.

[0142] By appropriate selection of the layers, the individual interconnected layers form at least a portion of one side of the battery pouch. This provides a variety of manufacturing advantages. It reduces the total number of layers required, simplifies manufacturing, and improves the reliability of the battery pouch in a roll-to-roll manufacturing process. In a roll-to-roll manufacturing process, the electrical connections, layers, and sealing areas are stored (at least for a period of time) on a roll with a radius of curvature so that the upper layer of a given section of the wireless band 102 has a slightly larger upper layer elongation due to the radius of curvature. Simplifying the overall design of the battery pouch and reducing the number of layers improves manufacturability and reduces the likelihood of sealing defects in the barrier and / or electrical connection failures.

[0143] like Fig.13 As illustrated in flowchart 1300 of FIG. 1 , a high-level method or process may include forming the electrochemical components of the battery on a bottom interconnect layer that serves as at least a portion of a bottom barrier layer in block 1305. A top interconnect layer that serves as at least a portion of a top barrier layer may be formed on the battery pouch in block 1310. Additional seals and / or sealing layers may be formed to complete the battery pouch in block 1315.

[0144] Fig.14 1400 is a flow chart of an example of a planar process, wherein Fig.14A , Fig. 14B , Fig. 14C , Fig.14D and Fig.14E Additional details are shown in the figure. Fig.14 As illustrated, initially there is a set of separate (but parallel) roll-to-roll processes for forming what will become the top and bottom interconnect layers of the wireless ribbon 102. During the manufacturing process, the top interconnect layer can be flipped and aligned with the bottom interconnect layer, where the top and bottom interconnect layers are laminated to each other. The entire process can be implemented in a roll-to-roll process.

[0145] Fig.14A The result of the initial steps 1402 and 1404 in the planar process is shown. A cathode layer with (MnO2-C-PVDF) ink and an anode layer on (Zn-C-PVDF) ink are printed onto a first interconnect layer corresponding to the bottom interconnect layer in the figure. The bottom interconnect layer serves as an impermeable battery pouch material. As an example, the first interconnect layer may include a liner or underside of a facestock material or a thermochromic paper.

[0146] Fig.14AAnode and cathode pairs are shown along the strip for what will become the first wireless tracking tag device 1450A and the anode and cathode pairs for the second wireless tracking tag device 1450B. Thus, in this example, as the roll (circle) rotates, anode and cathode regions are made by printing appropriate inks in the window / masked areas, thereby making a certain number of individual wireless tracking tags. The current collectors that are part of the anode and cathode regions or structures can be served by the conductive properties of the interconnect layer itself, or enhanced by additional coatings such as carbon or carbon nanotubes.

[0147] Fig. 14B The diagram shows that a cathode layer with (MnO2-C-PVDF) ink and an anode layer on (Zn-C-PVDF) ink are printed onto a second interconnect layer that will also serve as an impermeable battery bag material. In one embodiment, the anode and cathode inks, namely Zn-C and MnO2, are coated on top of the carbon, respectively. The carbon is coated on top of the aluminum-PET or on only PET in the interconnect layer. However, carbon is not always required on top of the aluminum PET. This generally corresponds to the results of steps 1410 and 1412. The second interconnect layer 118B can be a lining or underside of a face material material or a thermochromic paper. As illustrated, the second interconnect layer 118B can be a top interconnect layer. The top interconnect layer in this example also has two label devices along the wireless band. Conductive segments S1 and S2 (e.g., carbon, copper, carbon-coated copper, etc.) are formed to create what will become a series connection between two electrochemical cells in the final manufactured device.

[0148] Fig. 14C The processing step of applying electrolyte in the window regions over the anode and cathode regions over what will become the bottom interconnect layer is shown. This generally corresponds to step 1406.

[0149] Fig.14D The mounting of electrical components 1490, such as an RF wireless processor and an RF wireless communication chip (e.g., a Bluetooth processor and a Bluetooth wireless communication chip) is illustrated. Conductive traces are formed directly connected to the current collector to power the electrical components 1490. Programming of the firmware may also be performed. A pogo pin landing pad (not shown) may be provided for programming. Fig.14D Typically corresponds to step 1408.

[0150] Fig.14EThe diagram shows how the top interconnect layer is flipped and laminated to the bottom interconnect layer. This generally corresponds to steps 1414 and 1416. For example, in a roll-to-roll process, a mechanical fixture can be used to slowly twist and rotate the top interconnect layer to flip it. Registration techniques (e.g., using optical fiducial marks or other alignment techniques) can be used to align the flipped top interconnect layer. Other mechanical components can be used to form the lamination, including adhesives, transfer adhesives, and / or heat sealing techniques. This is what is called a planar design, in which the electrochemical cells are vertically stacked layers with vertical ion flow as indicated by the arrows.

[0151] Return to reference Fig.14 ,exist FIG. 14A to FIG. 14E In the process of forming the bottom interconnect layer, the initial process of forming the bottom interconnect layer can include forming the anode and cathode current collectors in step 1402. In step 1404, the cathode and anode ink patterns are formed. In step 1406, the electrolyte is applied. In step 1408, the electrical components are installed and programmed. For the top interconnect layer, in step 1410, the anode and cathode current collector regions are formed. In step 1412, the cathode and anode ink patterns are printed. In step 1414, the top interconnect layer is flipped and aligned with the bottom interconnect layer. In step 1416, the top layer is laminated to the bottom interconnect layer.

[0152] An example of a coplanar manufacturing process will now be described, which also includes flipping the top interconnect layer and laminating it to the bottom interconnect layer. Coplanar manufacturing has an interdigitated arrangement of anode and cathode regions with horizontal ion flow in each electrochemical cell (as previously described with respect to Fig. 12A and Fig. 12B Electrical traces are formed to form series connections between electrochemical cells. Fig.15 Flowchart 1500 of a method for forming wireless band 102 . Fig.15A , Fig. 15B , Fig. 15C , Fig.15D and Fig.15E Various aspects of the method are illustrated.

[0153] Fig.15AThe results of steps 1502 and 1504 are illustrated with respect to printing a cathode (e.g., MnO2-PVDF) ink and an anode (e.g., Zn-C-PVDF) ink onto a bottom interconnect layer 118A. The bottom interconnect layer will be used to form a portion of an impermeable battery bag. As an example, the bottom interconnect layer can be formed by a lining or underside of a thermochromic paper or facestock material. It should be understood that a current collector layer (e.g., carbon) may be included. Each individual electrochemical cell has an interdigitated anode 1215 and cathode 1210 region with lateral ion flow between the interdigitated fingers. Two interdigitated electrochemical cells are illustrated, which can be connected in series, for example, using electrical traces of aluminum or copper or other connections (such as inks including carbon, silver, or carbon nanotubes that form these connections). Thus, if each interdigitated coplanar cell produces 1.5V, then two in series produce approximately 3V. The anode layer and the cathode layer include a negative current collector and a positive current collector, respectively, which may be made of carbon, copper, aluminum, carbon-coated copper, carbon-coated aluminum, carbon nanotubes, and the like.

[0154] Fig. 15B The top interconnect layer is shown with a transfer adhesive area to which a powdered gel is applied (eg, brush-rolled). Fig. 15B Typically corresponding to the results of steps 1508 and 1510. The reference mark can be detected along the moving web, and the relative offset is calculated to determine where to apply the transfer adhesive. The transfer adhesive is patterned to 1) the edge seal area ("first area") and 2) the portion of the top interconnect that will form the electrolyte area ("second area"). The transfer adhesive forms the sticky side of the face material material. The electrolyte can be formed on the second area in two different ways. In one embodiment, guar gum, xanthan gum, or a similar powdered material that forms a gel when wetted is initially deposited in dry powder form. For example, it can be deposited in powder form, where it is brushed onto the adhesive pattern in the second area. In one embodiment, these second areas are later wetted by applying water vapor including an electrolyte. In another embodiment, electrolyte chemicals in dry powder form are included in powdered guar gum, xanthan gum, etc. that are brushed onto the adhesive pattern. Water vapor is then applied to wet these areas to form a gel electrolyte. In one embodiment, the top and bottom interconnect layers are processed to allow the top and bottom layers to be attached to each other to form a battery cell and battery pouch, with a transferred adhesive edge to form an edge seal.

[0155] Fig. 15C The gel is shown moistened (e.g., with water vapor) to form a semi-aqueous gel for the top layer. This corresponds to step 1512. As previously discussed, depending on the implementation details, the water vapor can include an electrolyte. Alternatively, the powdered gel material can include an electrolyte material (e.g., a chemical salt) in dry form that becomes chemically active in the semi-aqueous gel.

[0156] Fig.15D The diagram shows how electrical components (such as a Bluetooth processor and a communication chip) are mounted to the bottom interconnect layer. Programming of the microchip firmware may also be performed. This corresponds to the result of step 1506.

[0157] Fig.15E A top interconnect layer with gel electrolyte is shown to be laminated and sealed to a bottom interconnect layer with a transfer adhesive forming a seal of a battery pouch along the edges to form a battery pouch. For example, this may include flipping the top layer and aligning / registering it with the bottom layer. This corresponds to step 1516.

[0158] Return to reference Fig.15 , the process may include forming top and bottom barrier layers (e.g., on any suitable layer for forming an impermeable barrier), wherein the interconnect layer(s) form part of the battery pouch. Processing of the bottom layer may include forming a current collector region 1502, followed by printing 1504 interdigitated cathode and anode ink patterns. In the case of two electrochemical cells to be used in series, the series connection may be provided by aluminum, copper as part of the interconnect layer itself, or by an ink-based coating that may include carbon, carbon nanotubes, or silver. In step 1506, the electrical components are mounted on the bottom layer, along with any required programming (e.g., programming of firmware). For the top layer, in step 1508, an adhesive is applied in a selected area. In step 1510, a powdered gel is deposited on a selected area of ​​the adhesive. In step 1512, the deposited powdered gel is wetted by, for example, exposing it to a water vapor source (e.g., a fine mist, or, for some materials, steam). The water applied to the powdered gel may include an electrolyte. Alternatively, an electrolytic chemical (in a powdered dry form) may be added to the powdered gel material. In step 1514, the top layer is flipped, aligned with the bottom layer, and registered. In step 1516, the top layer and bottom layer are laminated together.

[0159] Fig.15 One advantage of the process is that the adhesive used to form the seal can also be used to form the electrolyte region.

[0160] refer to Fig.16 Flowchart and Fig.16A In some embodiments, the planar manufacturing process 1600 uses a folding process to form the wireless band 102. For example, a component can be used to force it to fold along a fold line. The folding process eliminates the need to precisely align two separate top and bottom interconnect layers. Thus, the manufacturing process includes forming the top and bottom interconnect layers on the same substrate / interconnect layer, mounting the processor and communication chip components, and folding and sealing to form the battery and battery pouch.

[0161] The folding process facilitates manufacturing in a roll-to-roll process because folding is easier to perform than precisely registering the separated top and bottom layers during the lamination stage. This is because the folding process forces precise alignment.

[0162] Another advantage of the folding process is that it allows three electrochemical cells to be coupled in series. Conductive traces can be formed to connect the top and bottom without the need for soldering, conductive adhesives or crimping.

[0163] Fig.16A The diagram illustrates how the fold lines and interconnect layers are patterned to form top and bottom interconnect layers after folding. Interconnect layer 1670 has top segment 1652 and bottom segment 1654 and fold line 1650 between top segment 1652 and bottom segment 1654. After folding, electrical traces may be formed as desired to connect the top and bottom layers.

[0164] exist Fig.16A In the example of , there are three anode / cathode pairs corresponding to three electrochemical cells in series, as illustrated by vertical arrows. There is a first anode / cathode pair corresponding to anode 1620A and a first cathode 1620A. There is a second anode / cathode pair corresponding to a second anode 1620B and a second cathode 1630B. There is a third anode / cathode pair corresponding to a third cathode 1630C and a third anode 1620C. This corresponds to what will become three electrochemical cells in series. There is a first series connection from a first connection layer S1 and a second connection layer S2. That is, S1 forms a series connection from the first cathode 1630A to the second anode 1620B. S2 forms a series connection from the second cathode 1630B to the third anode 1620C. A conductive trace forms a connection from the third cathode 1630B to a voltage input (e.g., 4.5V). A ground connection is made to the first anode 1620A.

[0165] For example, S1 and S2 may include carbon layers, aluminum layers, or copper layers. Folding and laminating / sealing on the fold lines (illustrated by the middle dashed lines) results in 3 electrochemical cells connected in series contained in the battery pouch to provide power for installed electrical components. For illustration purposes, the vertical arrows illustrate the vertical ion flow in the final battery structure.

[0166] In some embodiments, the material of the interconnect layer can be selected to form a Faraday cage or RF shield for the entire battery pouch. For example, a thin metal coating can be included as part of the interconnect layer to form a Faraday cage after folding and lamination.

[0167] Return to reference Fig.16, many aspects of the process are similar to the process steps of the previously described planar process, except that some process steps are completed on different segments of the same interconnect layer, and folding is used to fold different segments together. The top segment (above the fold line) forms the top interconnect layer after folding. The bottom segment (below the fold line) forms the bottom interconnect layer after folding. In box 1602, separate carbon anode and cathode current layers are formed on the second portion of the interconnect layer. In box 1604, adjacent cathode and anode ink patterns are patterned onto the first segment of the interconnect layer. In box 1606, the electrolyte is applied to the cathode and anode regions. In box 1608, electrical components are installed and firmware is programmed into the RF processor. For example, the programming of the firmware can also be performed using a pogo pin landing pad (not shown in the figure). In box 1610, a carbon anode / cathode current collector is connected in series to the second segment of the interconnect. In box 1612, adjacent cathode and anode ink patterns are printed onto the second segment. In box 1614, the first and second segments are folded along the fold line. In block 1616, the top and bottom interconnect layers are sealed for the battery pouch. As some examples, the seal may be formed using a heat lamination sealing process or by using a transfer adhesive.

[0168] In addition to the other fabrication techniques previously discussed, in some embodiments, ultrasonic welding is used to weld one interconnect layer to another.

[0169] Fig.17 and Fig.17A An example of how the folding process can be applied in the coplanar design of the wireless band 102 is shown. Fig.17A As shown, three interdigitated electrochemical cells 1730A, 1730B, and 1730C may be formed and connected in series to support operation of the chip at 3.0 volts or 4.5 volts, as shown. Fig.17A Many details of the processing are similar to the coplanar design described previously. However, the top section 1752 and the bottom section 1754 are patterned to form the top and bottom interconnect layers after folding on the fold line 1750. As previously discussed, the battery pouch can include a conductive layer or conductive coating so that after the folding process, a Faraday cage RF shield is formed around key components to eliminate the emission of unwanted radiation. Return to Reference Fig.17, there is a first section below the fold line, which will form a bottom interconnect layer after folding. There is a top section above the fold line, which will form a top interconnect layer after folding. The exemplary method includes forming a separated carbon collector area 1702. In box 1704, interdigitated cathode and anode ink patterns are printed on the bottom section of the interconnect layer. In box 1706, electrical components are mounted to the bottom section of the interconnect layer and the firmware is programmed. In box 1708, the top section of the interconnect surface material is coated with an adhesive in the selected area. In box 1710, a gel material in powder form (e.g., via a brush roll) is deposited on the adhesive-coated top section. In box 1712, the gel material is wetted to form a gel electrolyte. For example, water vapor including an electrolyte can be deposited. Alternatively, the dry powder can include an electrolyte chemical (e.g., a salt) in a dry form, so that wetting the gel material with water generates a semi-aqueous gel with an electrolyte. In box 1714, the first and second sections are folded along the fold line. In block 1716, the top and bottom interconnect layers of the folded structure are sealed to form a battery pouch around the interdigitated electrochemical cell.

[0170] Fig.18A 18 is a side cross-section of a battery pouch 1805 wireless tracking tag that expands on the previously described example of a wireless tracking tag having two electrochemical cells connected in series, the electrochemical cells being formed by a planar process with vertical ion flow in each electrochemical cell, with a planar conductive layer coupling the electrochemical cells in series. Fig.18A A battery comprising four electrochemical cells connected in series is shown with vertical ion flow in each electrochemical cell, with patterned planar conductive layer regions coupling the electrochemical cells in series.

[0171] For a planar stack design, an even number of electrochemical cells in series (e.g., 2, 4, 6, etc.) eliminates the need to form a separate connection (e.g., using a conductive tab) from the top planar conductive layer to the interconnect layer. That is, for an even number of electrochemical cells, the first electrochemical cell extends from a portion of the interconnect layer up to the planar conductive layer, and the next electrochemical cell in series extends from the planar conductive layer back down to the interconnect layer. This is in Fig.18B . This is true for two electrochemical cells, four electrochemical cells, or even a higher even number of electrochemical cells, such as six electrochemical cells. For an even number of vertical electrochemical cells in series, the process of forming the series connection is highly manufacturable. Thus, the manufacturing does not require overlapping tabs or other steps (such as forming conductive vias) that are difficult to implement in a low-cost, high-volume manufacturing process.

[0172] Fig.18A One aspect of wireless tracking tags is that they can route two or more different voltages from an electrochemical cell. Fig. 18CIn an example of , a battery having an even number of electrochemical cells 1880 in series (such as four cells in series) has a dual voltage output purpose to power a first circuit block with a first voltage 1882 (e.g., 3V) and a second circuit block with a second voltage 1884 (e.g., 6V) by routing the two different voltages to two different circuit blocks. For example, 3V may be routed to a circuit block that operates well at 3V. However, some types of circuits (such as some types of RF circuit blocks) function better at voltages greater than 3V.

[0173] Fig.18A Examples of can be fabricated using any of the techniques previously discussed for forming a vertical stack of series-connected electrochemical cells. The interconnect layers can be patterned to route dual voltages (e.g., 3V or 6V) to different circuit blocks, such as Fig. 18C As shown.

[0174] Fig.19A and Fig.19B Illustration of some of the issues associated with scaling up the area of ​​the electrochemical cell in a wireless tracking tag. Fig.19A , a series connection of electrochemical cells is illustrated, wherein each electrochemical cell 1902, 1904, and 1906 has an associated battery resistance (e.g., R1, R2, and R3, respectively). Fig.19B , the equivalent battery has a series equivalent voltage of all batteries in series 1910. The equivalent resistance is the combined series resistance of the series connected batteries corresponding to resistors R1, R2 and R3.

[0175] However, if Fig.19B As shown, individual resistances (e.g., the resistance of resistor R2) can be higher than the average. In thin-film batteries using graphite coatings, graphite coatings are notorious for high resistance compared to metal-based conductors. Graphite coatings are also prone to cracking. When multiple cells are connected in series, there is a multiplier effect on the probability of any one cell exhibiting a higher than normal resistance or disconnection.

[0176] There may also be a multiplying effect when scaling up the area of ​​the electrochemical cell for the formation of potential cracks or other defects, which, if they occur, could increase the resistance of the battery, or even create a disconnect.

[0177] like Fig.19C As shown, in one embodiment, the electrochemical cells of the wireless tracking tag are connected in series and in parallel. That is, instead of a single large 1.5V cell (e.g., Fig.19AInstead of a single large 1.5V cell 1904 having a nominal resistance R2, there may be a level with two or more cells in parallel (e.g., cells 1962, 1964, and 1966). Instead of a single large 1.5V cell 1906 having a nominal resistance R1, there may be a level with two or more strings of cells in parallel (e.g., cells 1972, 1974, and 1976). Thus, in each level of the battery there is a parallel electrical connection of cells, with the levels being electrically connected in series. There may be any reasonable number of levels connected in series (e.g., 2, 3, 4, etc.) and any reasonable number of cells in parallel in each level (e.g., 2, 3, etc.).

[0178] like Fig.19D As shown in the figure, Fig.19C The equivalent circuit has a set of parallel resistors for each cell. This means that if there is a defect in an individual cell (e.g., resistance R2-1 is higher than average or resistor R2-1 is disconnected), it will not be catastrophic to the use of the battery. The battery resistance will still remain within a limited range due to other equivalent resistors in parallel (e.g., R2-2 and R2-3). The series-parallel configuration of battery cells and their equivalent resistors results in a manufacturable process that is more robust to manufacturing variations and defects.

[0179] In some embodiments, wireless tracking tags use a nominally higher voltage thin film printed battery voltage (e.g., 6V) to power circuits with a lower safe operating voltage (e.g., 4.5V). In practice, thin film printed batteries with nominal (no-load) voltages of 3V or 6V are most easily manufactured for thin film ZnMn batteries, each with a nominal voltage of approximately 1.5V. As previously discussed, thin film printed batteries for wireless tracking tags are more complex to manufacture at intermediate nominal voltages (such as 4.5V) with environmentally friendly materials.

[0180] Wireless tracking tags can include a variety of different processors and other circuits. Some of these circuits can consume more power (and draw more current) when activated. Fig. 20AThe circuit that can be implemented on a wireless tracking tag is shown to be able to use a higher power thin-film printed battery voltage (e.g., 6V) to power a circuit block on the wireless tracking tag with an intermediate maximum operating voltage (e.g., an RF device 2010, such as an RF communication processor with a maximum safe operating voltage of 4.5V, or other RF communication circuits with a maximum safe operating voltage). In one embodiment, a voltage protection circuit is provided that can use a lower power device 2004 (e.g., using a timer or Bluetooth chip or other processor) to switch the power supply voltage to the load (e.g., switch 6V to a high power RF device (e.g., RF communication processor or other RF communication circuit).

[0181] exist Fig. 20A In the example of , the RF device 2010 has a certain maximum highest safe voltage, which may be, for example, a maximum voltage of about 4.5 V (or slightly lower, such as 4.2 V). Some commercial RF devices are designed to operate at about 4.5 V.

[0182] However, as previously discussed, a thin-film printed battery constructed from environmentally friendly materials with four 1.5V electrochemical cells in series has a nominal voltage of 6V. As an example, it can have an equivalent internal resistance in the range of 50 to 90 ohms, depending on the manufacturing details. This internal resistance can be beneficially used in a voltage control circuit with a Zener diode circuit to control the voltage of the RF device during the initial turn-on period.

[0183] exist Fig. 20A In the example of FIG. 1 , a complementary pair of p-FET and N-FET switches allow a lower power processor (or other circuit) to turn on the switch. When the lower voltage processor or circuit turns on the switch, 6V ​​is initially presented to the load, which includes a 4.5V tolerant RF device in parallel with a voltage protection circuit including a 4.5V Zener diode 2006 and a capacitor 2008.

[0184] When a load is applied, the Zener diode initially goes into reverse breakdown, which causes current to flow through the Zener to ground, thereby limiting the voltage presented to the RF device to no more than the Zener reverse breakdown voltage. However, while there is initially a high current drawn through the Zener diode 2006, the internal resistance of the thin film printed battery causes a voltage drop presented to the load, and therefore to the Zener diode. That is, as the RF device 2010 turns on and draws current, there is effectively a voltage divider in the circuit in the sense that some of the voltage of the battery is reduced due to the internal resistance of the battery. As the RF device 2010 turns on and draws current, the voltage drop created by the resistance of the thin film printed battery increases. After a certain initial turn-on period, the voltage drops below the range where the Zener diode 2006 is strongly conducting. The Zener diode 2006 begins to draw less current and consume less power. The Zener diode 2006 stops conducting strongly and is effectively turned off.

[0185] This method utilizes the internal resistance R1 of the thin film printed battery, the Zener diode breakdown voltage, the capacitance value of capacitor 2008, the turn-on voltage of the RF device 2010 (e.g., RF processor), and the current drawn by the RF device (e.g., RF processor) when turned on. By selecting these parameters, the Zener diode 2006 is used to prevent overvoltage on the RF device 2010 from exceeding the maximum safe operating voltage when the 6V battery is initially presented to the load, however after a short period of time, the voltage protection circuit enters a second operating mode during normal use of the RF device, wherein the Zener diode ceases to conduct strongly (effectively turns off), and the Zener diode does not waste power during normal operation of the RF device.

[0186] Fig. 20B The diagram shows how the Zener diode 2006 sinks current in reverse breakdown during the initial turn-on time constant to protect the RF device 2010 from overvoltages that exceed the maximum voltage of the RF device. However, after the turn-on time constant, the voltage at the load drops enough that the Zener diode 2006 no longer conducts significant current. During normal operation of the RF device 2010, the current drawn through the Zener diode 2006 and the power consumed by the Zener diode 2006 are not significant.

[0187] Fig. 20BThe voltage applied to the load and therefore to the RF device 2010 is illustrated. Curve 2005 illustrates how the voltage applied to the load would initially rise to approximately 6V without the voltage protection provided by the Zener diode 2006 and burn out the RF device 2010 which is designed to operate at a lower safe maximum voltage, such as 4.5V. Curve 2010 illustrates the voltage with a voltage protection circuit including the Zener diode 2006 and associated capacitor 2008. The voltage at the load initially rises until the Zener diode 2006 turns on. There is a finite time period t0 when the Zener diode 2006 turns on and draws a large amount of current. However, the current of the Zener diode 2006 decreases after time t0 because once the RF device 2010 begins to draw a large amount of current, the voltage drop created by the internal resistance R1 of the battery reduces the applied voltage by acting as a voltage divider.

[0188] Fig. 20A The circuit exploits the fact that thin-film printed batteries, formed by a series connection of 1.5V electrochemical cells, have significant resistance. Fig. 20A The circuit uses a small number of relatively inexpensive components to perform complex functions to achieve voltage protection while consuming minimal power during normal operation of the RF device.

[0189] Fig. 20C Graphics Fig. 20A A general design method for a circuit of a wireless tracking tag is described. In box 2090, when designing a thin film printed battery for a wireless tracking tag, there are some nominal internal resistance ranges for the series connection of electrochemical cells. For example, for a series connection of four 1.5V electrochemical cells to produce a nominal 6V battery, the range can be 50 to 90 ohms. However, different ranges of battery resistance are also possible depending on various factors. In box 2092, the circuit designer selects the RF device to be used, which has turn-on characteristics, maximum safe operating voltage, and operating current parameters. In box 2094, the Zener diode reverse breakdown voltage and the capacitance associated with the Zener diode are selected. For example, for a given thin film printed battery with a nominal 6V and an internal resistance of 50 to 90 ohms, the Zener diode characteristics and capacitance can be slightly adjusted to achieve the desired voltage protection of the RF device.

[0190] Fig.21A An embodiment is shown in which a wireless tracking tag RF device 2110 (e.g., an RF communication processor) is powered by a thin film battery cell 2105. An RF filter circuit 2120 can be provided that utilizes a thin film aluminized PET inductor and / or capacitor 2115 formed from layers that are compatible with the other layers of the wireless tracking tag. This reduces parts content and manufacturing costs compared to using discrete capacitors and inductors. Even eliminating a single discrete capacitor can be important in terms of manufacturability.

[0191] Fig.21B An example of an aluminized PET structure is shown. The example embodiment has a 38 micron thick PET layer, a 15 micron thick top aluminum layer, and a 10 micron thick bottom aluminum layer. These layer thicknesses can be adjusted to be compatible with the design and manufacture of the other layers of the wireless tracking tag.

[0192] refer to Fig. 21C , an illustrative example of an RF circuit may be a 50 ohm impedance matching circuit between a wireless RF device and an antenna. For example, the circuit may be a Pi filter for filtering noise, which has an equivalent circuit of two capacitors and one inductor. The capacitor values ​​of capacitors C1 and C2 may, for example, have values ​​in a range between 1.2 pF and 6 pF. The inductor may have a value between 2 nH and 5 nH. As an illustrative example, a 1.2 pF capacitor C1 may be fabricated as Fig.21B The patterned rectangle of the aluminized PET structure has a surface size of approximately 1.33 mm × 1.5 mm and a total surface area of ​​1.95 mm 2 The capacitance is given by the formula C = EA / d, where E = dielectric constant, A is the area and d is the spacing. For PET, E is about 3.5. Assume A = 1.95 mm 2 And d = 38 microns, then C is 1.5 pF.

[0193] Eliminating the need for one or more discrete capacitors and / or inductors reduces the number of discrete components needed to implement a wireless tracking tag, thereby reducing manufacturing costs.

[0194] refer to Fig.22A , an exemplary method of forming an electrical connection between conductive layers may include forming a label layer structure having at least two conductive layers separated by an intermediate layer in block 2202, forming a perforation in block 2204, and filling a void in the perforation with a conductive material (such as by using a conductive ink or a conductive epoxy). For example, the conductive ink or the conductive epoxy may include silver flakes or nickel balls.

[0195] This method of forming an electrical connection is similar to forming conductive vias in a printed circuit board (PCB). Conductive vias are formed in a PCB by forming holes and copper plating. However, the materials herein are different because in PCBs, there are copper plating and other techniques that are incompatible with making vias for flexible wireless tracking tags in a roll-to-roll manufacturing process.

[0196] A number of different implementation options for improving manufacturing and improving battery life will now be described. One aspect of battery life is associated with the problem of electrolytic corrosion. Fig.23AA cross section of a portion of an embodiment of a wireless tracking tag protecting an aluminum laminate from electrolytic corrosion is shown. In this embodiment, a PET film is employed (which is laminated between two layers of aluminum foil in a preferred embodiment). The aluminum laminate serves as an interconnect layer, forming both the cathode and anode current collectors of the stacked structure and electrically connecting them to the electrical components of the wireless band.

[0197] However, within the pocket areas, electrolytes such as ZnCl2 can corrode the aluminum foil, reducing its conductivity and leading to battery failure. One way to minimize this corrosion is to coat the aluminum current collector with printed graphite and a polymer such as PVDF (poly(vinylidene fluoride)). However, this may not be enough to avoid corrosion over time from aqueous electrolytes, which can slowly penetrate the graphite coating and corrode the underlying aluminum. Therefore, in one embodiment, the wireless band is patterned without aluminum forming a current collector in the sealed pocket area. Instead, the aluminum is patterned adjacent to the pocket area of ​​the cell, with the graphite layer forming a bridge between the current collector and the aluminum-plated interconnect layer. This Fig.23A The pocket area generally includes the top sealing film, the bottom PET layer and the area between the side adhesive areas. For illustration purposes, a 15 micron thick aluminum layer is shown adjacent to the pocket area with the graphite layer forming a bridge. This manufacturing ensures that the electrolyte does not come into contact with the aluminum.

[0198] Fig. 23B A variation of the same principle is shown where a conductive ink, such as silver, is printed on or below the graphite layer at the interface between the graphite current collector and the aluminum interconnect layer. Fig.23C The illustration includes a cross section of other portions of the bag.

[0199] Fig.23D One embodiment variation is illustrated in which the silver ink is patterned in a grid pattern not only at the interface, but across the entire graphite-coated current collector area to increase the conductivity of the graphite and reduce the internal resistance of the battery. Fig.23E Graphics Fig.23D An example of an additional layer of bag is shown.

[0200] Fig.24 A cross section of a battery pouch for a wireless tracking tag illustrating another variation to increase battery life. Removing the aluminum as part of the current collector fabricated as either the cathode or anode avoids problems associated with aluminum corrosion by common electrolytes such as ZnCl2. However, such modifications have additional considerations because the substrate forming one side of the battery pouch also serves as an interconnect layer and no longer provides a barrier layer to protect against oxidation and evaporation of the active electrochemical components. PET itself is not an impermeable material, and over time, oxygen and H20 can migrate through the PET material, causing evaporation of the aqueous electrolyte and battery failure on the circuit.

[0201] To address this problem, a second layer of interconnects can be added to the bottom side of the PET layer, which also serves as a ground plane and interconnect while also forming an impermeable bag layer. Fig.24 As illustrated, an additional aluminum layer may be added to the bottom of the PET layer to serve as a bottom impermeable bag layer.

[0202] Fig.25 A cross section of a battery pouch for a wireless tracking tag that eliminates the need for plastic-based materials to meet growing environmental impact regulations. The elimination of plastic-based materials makes the wireless tracking tag completely recyclable and disposable. In some embodiments, the PET layer can be replaced with a paper layer. As illustrated, the bottom aluminum layer serves as an impermeable bag layer. A thin layer of acrylic adhesive (or other protective adhesive material) between the paper layer and the bottom aluminum layer separates the aqueous electrolyte from the aluminum and avoids corrosion. However, some leakage may occur in the horizontal direction. In one embodiment, this is addressed by impregnating points A and B with a material to make the paper more impermeable to H20 and O2. As an example, a wax or sol-gel process can be used for points A and B. Alternatively, the paper can be patterned using silicone additives or other environmentally friendly sealing mechanisms to make it impermeable.

[0203] Fig.26A , Fig.26B , Fig.26C and Fig.26D Various aspects of an embodiment using an interconnect layer as a separator for bifacial cell formation are illustrated. Personalized top seal area. The reason for the need for personalized top seal is that cell formation must be performed before component assembly. Cells are typically screen printed or coated on a flat surface in various ways via gravure or rotary flexographic printing. This requires cell formation to be performed before component assembly. Components (such as RF processors) will impart protrusions and hinder the printing process. Fig.26A Shown is a cross section of an interconnected spacer layer which may, for example, comprise a paper layer, top and bottom aluminum layers, and an additional acrylic adhesive layer. Fig.26B A top view and a side cross-sectional view are shown. The side cross-sectional view shows the interconnected separator layer, the battery layer, etc. This method uses the interconnected layer itself as a separator for the battery formation. In this embodiment, the separator is considered to be the main material and also acts as an interconnected layer. It can be described as an interconnected separator. It can be constructed as paper or a porous polypropylene material such as Celgard. The interconnected separator includes a porous material (or a material that can be made porous) to facilitate ion transfer within the electrolyte between the anode and cathode of the battery. In one embodiment, the interconnected separator is a cellulose-based paper material laminated with aluminum foil on both sides. This is a common material typically used to make environmentally friendly RFID tags.

[0204] In one embodiment, the interconnecting separator is impregnated with a polymer around the border of each cell, but this can be implemented using a printing method. For example, a sealant in liquid form can be patterned via a printing process to isolate each separator cell area.

[0205] refer to Fig.26C and Fig.26D This method of using interconnected separators supports a continuous roll-to-roll manufacturing approach. Bifacial cell manufacturing makes the material flatter, eliminating large raised areas and uneven levels found in some other manufacturing processes. This approach also supports the manufacture of a variety of parallel and series cell configurations.

[0206] For the purpose of illustration and description, the foregoing description of the implementation of the present technology and technology has been presented. It is not intended to be exhaustive or limit the present technology and technology to the precise form disclosed. According to the above teachings, many modifications and variations are possible. It is intended that the scope of the present technology and technology is not limited by this detailed description. The present technology and technology can be implemented in other specific forms without departing from its spirit or basic characteristics. Similarly, the specific naming and division of modules, routines, features, attributes, methods and other aspects are not mandatory or important, and the mechanism for implementing the present technology and technology or its features can have different names, divisions and / or formats. In addition, the modules, routines, features, attributes, methods and other aspects of the present technology can be implemented as software, hardware, firmware or any combination of the three. In addition, in the case where a component (an example of which is a module) is implemented as software, the component can be implemented as a stand-alone program, a part of a larger program, a plurality of separated programs, static or dynamic link libraries, kernel loadable modules, device drivers and / or computer programming, each and any other way now known or in the future. Additionally, the present technology and technology are in no way limited to the implementation of any specific programming language or any specific operating system or environment. Thus, the disclosure of the technology and techniques is intended to be illustrative rather than limiting.

Claims

1. A wireless tracking tag, comprising: Flexible substrate; an interconnect layer formed on the flexible substrate and patterned to electrically couple a plurality of electrical circuits including an RF communication processor and an RF communication circuit configured to generate tracking information; and A battery formed on the flexible substrate and comprising a cathode coating and an anode coating, wherein a battery pouch is formed on the interconnect layer, the battery pouch containing the electrochemical components of the battery to form an impermeable barrier to gases or moisture that are detrimental to the battery life for electrolyte chemicals, the electrolyte chemicals including at least one member from the group consisting of ZnSO4, ZnCl2, MnSO4 and AlCl4.

2. The wireless tracking tag tape of claim 1, wherein the interconnect layer comprises an aluminum layer.

3. The wireless tracking tag tape of claim 1, wherein the RF communication processor and the RF communication circuit are configured to remain in a power saving sleep mode during storage until activated for use.

4. The wireless tracking tag tape of claim 1, wherein the wireless tracking tag tape is formed in a roll-to-roll process, wherein the RF communication processor and the RF communication circuit of at least one individual wireless tracking tag are activated after being separated from a roll.

5. The wireless tracking tag strap of claim 1, wherein the wireless tracking tag strap includes a coil antenna tuned to resonate at a wake-up frequency and to generate a wake-up voltage in response to engagement with a user device having a transceiver emitting wireless signals at the wake-up frequency.

6. The wireless tracking tag of claim 1, wherein the battery comprises at least two electrochemical cells, the electrochemical cells being formed in series by a planar process, wherein there is a vertical ion flow in each electrochemical cell, wherein a planar conductive layer couples the two electrochemical cells in series.

7. The wireless tracking tag of claim 1, wherein the battery comprises at least two electrochemical cells formed in series by a coplanar process, wherein each electrochemical cell has a lateral ion flow between an interdigitated cathode and an anode, wherein a planar conductive layer couples the two electrochemical cells in series.

8. The wireless tracking tag of claim 1, wherein the battery comprises three electrochemical cells connected in series using electrical traces formed on the flexible substrate, the electrical traces electrically coupling a top layer to a bottom layer.

9. The wireless tracking tag of claim 1, wherein the battery comprises three electrochemical cells connected in series using electrical vias formed in the flexible substrate, the electrical vias electrically coupling a top layer to a bottom layer.

10. The wireless tracking tag of claim 1, wherein the battery comprises an even number of electrochemical cells, the electrochemical cells being formed in series by a planar process with vertical ion flow in each electrochemical cell, wherein a patterned planar conductive layer couples the four electrochemical cells in series.

11. The wireless tracking tag of claim 10, wherein the battery comprises at least four electrochemical cells, the electrochemical cells being formed in series by a planar process, wherein there is a vertical ion flow in each electrochemical cell, and wherein the patterned planar conductive layer couples the four electrochemical cells in series.

12. The wireless tracking tag of claim 1, wherein the battery comprises a series connection of at least two stages of electrochemical cells formed by a planar process, wherein there is a vertical ion flow in each electrochemical cell of each stage of electrochemical, and wherein each stage of electrochemical cells has at least two electrochemical cells connected in parallel.

13. The wireless tracking tag of claim 12, the battery comprising a series connection of four electrochemical cells, wherein each of the four stages has at least two electrochemical cells connected in parallel.

14. The wireless tracking tag of claim 1 , further comprising a voltage control circuit for protecting a load of an RF device, the voltage control circuit comprising a Zener diode, wherein a Zener diode breakdown voltage is selected to regulate the voltage applied to the load to within a safe voltage of the RF device during an initial time period when a battery voltage is switched to the load, the voltage control circuit being configured for the Zener diode to enter a low current conduction mode after the initial time period.

15. The wireless tracking tag of claim 14, wherein the RF device comprises at least one of the RF communication processor and the RF communication circuit.

16. The wireless tracking tag of claim 15, wherein the voltage control circuit comprises a Zener diode having an associated capacitance in parallel with the load.

17. The wireless tracking tag of claim 1, further comprising forming at least one of a capacitor and an inductor on one or more layers formed on the flexible substrate.

18. The wireless tracking tag of claim 17, wherein the at least one of a capacitor and an inductor is used in an RF filter circuit of the wireless tracking tag.

19. The wireless tracking tag of claim 1, wherein the flexible substrate comprises a PET substrate.

20. The wireless tracking tag of claim 1, wherein the flexible substrate comprises a paper substrate.

21. The wireless tracking tag tape of claim 1, wherein the battery is coated onto the interconnect layer.

22. The wireless tracking tag tape of claim 1, wherein the battery is printed onto the interconnect layer.

23. The wireless tracking tag of claim 1, further comprising a conductive via formed between two conductive planes using a perforation, wherein a void in the perforation is filled using a conductive ink or a conductive epoxy.

24. The wireless tracking tag of claim 1, further comprising a conductive via formed between two conductive planes using a perforation, wherein a void in the perforation is filled using a conductive ink or a conductive epoxy.

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