Embedded Thin Film Battery in PCB Layer Stack
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Solution Overview
Problem
The challenge is to efficiently integrate electrochemical cells, such as thin-film batteries, into printed circuit boards (PCBs) to maximize space utilization, protect sensitive materials, and enhance the PCB's functionality and robustness against environmental factors while minimizing thickness and external attachment complexities.
Innovation Solution
The integration of fully encapsulated electrochemical cells within the PCB layers, allowing for internal and external access, using a layer stack with insulating and conducting layers, and embedding the cells between these layers to provide protection and functionality, with methods including the use of bonding layers and conductive reinforcement for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrochemical cells are attached to the surface of PCB, then ease of manufacture is improved, but space utilization deteriorates
Solution Approach 1:
The patent transitions from surface-mounted battery attachment (2D) to embedded battery integration within PCB layers (3D). The battery is positioned between insulating layers of the PCB, utilizing the vertical dimension and internal space rather than occupying valuable surface area, thereby resolving the contradiction between ease of manufacture and space utilization.
Solution Approach 2:
The battery is nested within the PCB structure itself, specifically embedded between insulating layers. This nesting approach allows the battery to be housed within the existing PCB architecture rather than attached externally, maximizing space utilization while maintaining manufacturability through integrated fabrication processes.
2Area of moving object
If electrochemical cells are embedded within PCB layers, then space utilization is improved, but device complexity increases
Solution Approach 1:
The PCB structure serves multiple functions: it provides mechanical support for circuits and simultaneously houses the electrochemical battery between its insulating layers. This multi-functionality reduces overall device complexity by eliminating separate battery packaging and mounting structures, as the PCB itself becomes the battery housing.
Solution Approach 2:
The patent merges the battery housing function with the PCB structure. The insulating layers of the PCB serve dual purposes as both electrical insulation and battery encapsulation, eliminating the need for separate battery cans or packaging and thereby reducing device complexity despite the embedded configuration.
3Ease of manufacture
If sensitive materials are exposed to environment, then ease of manufacture is improved, but reliability deteriorates
Solution Approach 1:
The battery is fully encapsulated within the PCB structure during the manufacturing process, before the device is put into service. The insulating layers are already in place to provide environmental protection, preventing exposure of sensitive battery materials to harmful factors throughout the device's operational life while maintaining manufacturing simplicity through integrated fabrication.
Solution Approach 2:
The PCB's insulating layers provide pre-established protection against environmental factors such as moisture, oxygen, and contaminants. This beforehand cushioning ensures that sensitive battery materials are shielded from degradation before any harmful exposure can occur, thereby enhancing reliability without complicating the manufacturing process.
4Reliability
If PCB thickness is increased to accommodate embedded cells, then protection is improved, but compactness deteriorates
Solution Approach 1:
The patent utilizes thin insulating PCB layers to encapsulate the battery. These thin film structures provide adequate environmental protection while minimizing the increase in overall PCB thickness, thereby maintaining compactness. The thin insulating layers are sufficient to shield sensitive battery materials without requiring excessive thickness.
Data Source
AI summary
The present invention relates to, for example, printed circuit boards having a thin film battery or other electrochemical cell between or within its layer or layers. The present invention also relates to, for example, electrochemical cells within a layer stack of a printed circuit board.