PORTABLE ENERGY COLLECTION AND STORAGE DEVICE, METHOD OF PRODUCTION, AND METHOD OF USE
20210020999 ยท 2021-01-21
Inventors
Cpc classification
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E60/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01L25/167
ELECTRICITY
H01M2220/30
ELECTRICITY
International classification
H01M10/46
ELECTRICITY
H01L25/16
ELECTRICITY
Abstract
A portable energy collection and storage device includes an electrically and thermally insulating substrate. At least one energy collection device is integrated into the electrically and thermally insulating substrate. At least one energy storage device is integrated into the electrically and thermally insulating substrate and is electrically coupled to the at least one energy collection device. A set of electrical contacts is integrated into the electrically and thermally insulating substrate and electrically coupled to the at least one energy storage device. The electrically and thermally insulating substrate has a thickness less than or equal to 1 mm.
Claims
1. A portable energy collection and storage device, comprising: an electrically and thermally insulating substrate; at least one energy collection device integrated into the electrically and thermally insulating substrate; at least one energy storage device integrated into the electrically and thermally insulating substrate and electrically coupled to the at least one energy collection device; and a set of electrical contacts integrated into the electrically and thermally insulating substrate and electrically coupled to the at least one energy storage device, wherein the electrically and thermally insulating substrate has a thickness less than or equal to 1 mm.
2. The portable energy collection and storage device of claim 1, wherein the at least one energy collection device and the at least one energy storage device are laterally arranged across the electrically and thermally insulating substrate.
3. The portable energy collection and storage device of claim 1, wherein the at least one energy collection device and the at least one energy storage device form a vertical stack that is integrated in the electrically and thermally insulating substrate.
4. The portable energy collection and storage device of claim 1, wherein the at least one energy collection device comprises at least two energy collection devices forming a vertical stack that is integrated in the electrically and thermally insulating substrate, and the at least one energy storage device and the vertical stack are laterally arranged across the electrically and thermally insulating substrate.
5. The portable energy collection and storage device of claim 1, wherein the at least one energy collection device is a solar cell, piezoelectric energy generator, fuel cell, microbial fuel cell, thermoelectric generator, or radio frequency energy harvesting device.
6. The portable energy collection and storage device of claim 1, wherein the at least one energy collection device comprises: a plurality of energy collection devices, each electrically coupled to the at least one energy storage device, wherein at least two of the plurality of energy collection devices are configured to collect energy using different energy sources.
7. The portable energy collection and storage device of claim 6, wherein a first and second energy collection devices of the at least two of the plurality of energy collection devices are arranged in a vertical stack, the first energy collection device is arranged on a first side of the at least one energy storage device in the vertical stack and the second energy collection device is arranged on a second side of the at least one energy storage device in the vertical stack.
8. The portable energy collection and storage device of claim 6, wherein the plurality of energy collection devices are arranged in a vertical stack and comprise: a solar cell arranged in the vertical stack so that it is exposed to light; a thermoelectric generator arranged below the solar cell in the vertical stack.
9. The portable energy collection and storage device of claim 8, wherein the thermoelectric generator comprises a warm layer and a cold layer, the warm layer is arranged adjacent to the solar cell, and the at least one energy storage device is arranged in the vertical stack between the warm and cold layers.
10. The portable energy collection and storage device of claim 7, wherein the at least one energy collection device and the at least one energy storage device form a vertical stack that is integrated in the electrically and thermally insulating substrate, the device further comprising: through substrate vias passing through a substrate of one of the at least one energy collection device to the at least one energy storage device so as to electrically connect the at least one energy collection device and the at least one energy storage device to each other.
11. A method for forming a portable energy collection and storage device, the method comprising: integrating at least one energy collection device into an electrically and thermally insulating substrate; integrating at least one energy storage device into the electrically and thermally insulating substrate; electrically coupling the at least one energy collection device to the at least one energy storage device; integrating a set of electrical contacts into the electrically and thermally insulating substrate; and electrically coupling the set of electrical contacts with the at least one energy storage device, wherein the electrically and thermally insulating substrate has a thickness less than or equal to 1 mm.
12. The method of claim 11, wherein the at least one energy collection device and the at least one energy storage device form a vertical stack that is integrated into the electrically and thermally insulating substrate, the method further comprising: forming the vertical stack of electronic devices by forming the at least one energy collection device; forming the at least one energy storage device; and bonding the at least one energy collection device and the at least one energy storage device to form the vertical stack.
13. The method of claim 12, further comprising: forming at least one via through a substrate of one of the at least one energy collection device and the at least one energy storage device to form the electrical coupling between the at least one energy collection device and the at least one energy storage device.
14. The method of claim 12, wherein the bonding is performed using an epoxy-based resin with a single monomer containing eight epoxide groups.
15. The method of claim 12, wherein the at least one energy collection device includes first and second energy collection devices and the forming of the vertical stack of electronic devices further comprises: bonding the first energy collection device on a first side of the at least one energy storage device; and bonding the second energy collection device on a second side of the at least one energy storage device.
16. The method of claim 12, wherein the at least one energy collection device includes a solar cell and a thermoelectric generator, and the forming of the vertical stack of electronic devices further comprises: bonding the thermoelectric generator to the at least one energy storage device; and bonding the solar cell to the thermoelectric generator so that the solar cell is arranged at a top of the vertical stack of electronic devices.
17. A method of using a portable energy collection and storage device, the method comprising: arranging the energy collection and storage device in an environment to collect energy, wherein the energy collection and storage device includes an electrically and thermally insulating substrate having at least one energy collection device and at least one energy storage device integrated into the electrically and thermally insulating substrate and the at least one energy storage device is electrically coupled to the at least one energy collection device; and coupling the energy collection and storage device to an energy consuming device via a set of electrical contacts integrated into the electrically and thermally insulating substrate and electrically coupled to the at least one energy storage device, wherein the electrically and thermally insulating substrate has a thickness that is less than or equal to 1 mm.
18. The method of claim 17, wherein the arranging of the energy collection and storage device in the environment to collect energy comprises: arranging the energy collection and storage device so that it is exposed to light.
19. The method of claim 17, wherein the arranging of the energy collection and storage device in the environment to collect energy comprises: arranging the energy collection and storage device on an electronic device so that the energy collection and storage device is exposed to heat generated by the electronic device.
20. The method of claim 17, wherein the at least one energy collection device is a piezoelectric device configured to generate energy based on compression, and the arranging of the energy collection and storage device in the environment to collect energy comprises: arranging the energy collection and storage device underneath an object so that piezoelectric device is compressed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
DETAILED DESCRIPTION
[0019] The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of an energy collection and storage device and method of production and use.
[0020] Reference throughout the specification to one embodiment or an embodiment means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases in one embodiment or in an embodiment in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
[0021] Referring now to
[0022] As will be appreciated, in the embodiment of
[0023] In an embodiment, the electrically and thermally insulating substrate 102 can be, for example, plastic. Moreover, in an embodiment, the electrically and thermally insulating substrate 102 can have a rectangular shape. The electrically and thermally insulating substrate 102 has the general shape of a credit card, which typically conform to ISO/IEC 7810, format ID-1, which is 85.6053.98 mm and has rounded corners with a radius of 2.88-3.48 mm and a thickness of approximately 0.76 mm. Although the ISO/IEC 7810, format ID-1 specifies a thickness of approximately 0.76 mm, a thickness that is less than or equal to 1 mm can still fit within the compartments designed for an approximately 0.76 mm thick card. This shape can be considered as rectangular even though it can have rounded corners. This form factor is particularly advantageous because it allows the portable energy collection and storage device 100A and 1008 to be carried in a compartment of a wallet, pocketbook, etc. that is already sized for credit cards. An energy storage device 1048, such as a thin-film battery, can be incorporated into a substrate conforming to ISO/IEC 7810, format ID-1 and provide approximately four hours of standby and one to one and one-half hours of talk time of power to a smartphone. It should be recognized, however, that the portable energy collection and storage device can have other form factors that also make it convenient for a person to carry, compared to the conventional bulky replacement batteries and external power chargers.
[0024] As schematically illustrated in
[0025] In the embodiments illustrated in
[0026] The at least one energy collection device 104A and the at least one energy storage device 104B can be any type of device that can fit within the form factor of the portable energy collection and storage device 100A. The at least one energy collection device 104A can operate on any type of energy generation principal, such as solar, thermal, pressure, etc. For example, the at least one energy collection device 104A can be a micro-scale solar cell, piezoelectric generator using thin film or nano-structured devices, micro-scale fuel cell, microbial fuel cell, thermoelectric generator, and/or radio frequency-based energy harvesting device (e.g., an inductive charge collection device, such as, for example, those conforming to the Qi inductive wireless charging standard). The at least one energy storage device 1048 can be, for example, a thin-film or nano-structured battery. It will be recognized that the aforementioned energy collection and energy storage devices are well-known structures that are commercially available. It should be recognized that the aforementioned energy collection and energy storage devices are examples of such devices and other types of energy collection and energy storage devices can be employed.
[0027] As discussed above, two energy collection devices can be formed into a vertical stack that includes the at least one energy storage device 1048. When a plurality of energy collection devices 104A are incorporated into the vertical stack, the energy collection devices 104A can collect energy using different energy sources. For example, the vertical stack 104 can include a solar cell arranged on one side of the stack so that it is exposed to ambient light and a thermoelectric generator arranged below the solar cell. Specifically, a first part of the thermoelectric generator can be arranged directly adjacent and below the solar cell to absorb heat generated by the solar cell, an energy storage device can be arranged directly adjacent to the first part of the thermoelectric generator, and a second part of the thermoelectric generator can be arranged directly adjacent and below the energy storage device. Thus, the first part of the thermoelectric generator can be the hot layer of the thermoelectric generator and the second part of the thermoelectric generator can be the cold layer of the thermoelectric generator such that the thermoelectric generator generates electricity based on the temperature difference between the hot and cold layers. It will be appreciated that the terms hot and cold are intended to identify that a temperature difference exists between the two layers and is not intended to specify a particular temperature or range of temperatures for these layers. Thus, this embodiment increases the power generation density by taking advantage the waste heat generated by the solar cell that is not converted into electricity by the solar cell.
[0028] Although the portable energy collection and storage devices 100A and 100B include a set of external electrical contacts 106, external contacts are not required. For example, referring now to
[0029] A method for forming a portable energy collection and storage device will now be described in connection with the flowchart of
[0030] Arranging the at least one energy collection device 104A and the at least one energy storage device 104B in a vertical stack (as illustrated in
[0031] Moreover, employing thinner substrates for the electronic devices does not address all of the technological challenges for forming a three-dimensional integrated circuit. Specifically, vertically integrated electronic devices in the form of a three-dimensional integrated circuit (3D-IC) are typically produced by either forming subsequent electronic devices on top of the existing stack of electronic devices or the electronic devices can be formed separately and then stacked together. Forming subsequent electronic devices on top of the existing stack of electronic devices is problematic from a thermal perspective because forming the subsequent electronic device requires temperatures that will destroy the existing stack of electronic devices. Forming the electronic devices separately requires releasing the individual electronic devices from their original substrate, aligning the individual electronic devices with other electronic devices in the vertical stack, bonding the electronic devices of the stack, and forming vertical interconnects to electrically couple the electronic devices in the vertical stack.
[0032] In order to address these problems, a method for low temperature three-dimensional integration of the electronic devices in the vertical stack is provided according to an embodiment, which will be discussed in more detail in connection with
[0033] A first electrical device layer 406, which includes a flexible substrate carrying an electronic device, is placed on top of the PMMA layer 404 on the carrier wafer 402 (step 310 and
[0034] A second electrical device layer 410, which includes a flexible substrate carrying an electronic device, is then placed on the spin-coated SU-8 408 (step 320 and
[0035] The spin-coated SU-8 408 is then etched to form holes 412 for the through-silicon vias that will be subsequently formed to electrically couple the first 406 and second 410 electrical device layers (step 330
[0036] A conductive seed layer 414 (e.g., comprising 10 nm of chromium and 150 nm of gold) is then deposited on the PMMA layer 404 and the second electrical device layer 410 (step 335 and
[0037] A photoresist 416 is spin coated on the conductive seed layer 414 (step 340 and
[0038] The photoresist 416 can then be developed to grow the through-silicon vias 418 (step 345 and
[0039] Once the photoresist 416 is removed, the growth of the electrically conductive vias 419 is performed using electrochemical deposition of the conductive seed layer 414 (step 350 and
[0040] The conductive seed layer 414 is etched to remove excess metal (step 355 and
[0041] Although the method of
[0042] As will be appreciated from the discussion above, the temperatures used for forming the flexible three-dimensional electronic device are around 100 C., which is significantly less than the 250-450 C. temperatures used in conventional CMOS processing. This allows the formation of electrically conductive vias through the polymer layer without affecting the mechanical or chemical stability of the polymer layer. Thus, the disclosed embodiments provide a flexible three-dimensional electronic device that exhibits good mechanical integrity during flexing, and accordingly allows for the electronic device to conform to various shaped objects.
[0043] This method of three-dimensional integration of the electronic devices in the vertical stack of electronic devices uses temperatures that allow forming the electronic devices on top of one another without destroying the existing devices in the stack, and thus avoids the alignment, bonding, and electrical coupling issues of forming the electronic devices separately and then integrating them into the vertical stack. This method also allows the formation of a stack of electronic devices having heterogeneous substrates, which provides great flexibility in the types of electronic devices integrated into a three-dimensional integrated circuit.
[0044] Exemplary methods of using the disclosed portable energy collection and storage device will now be described in connection with
[0045] In the example illustrated in
[0046] In the example illustrated in
[0047] In the example illustrated in
[0048] Returning to
[0049] The energy collection and storage device can also charge an energy consuming device via an indirect contact, an example of which is illustrated in FIG. 6G. Specifically, the energy collection and storage device 600G includes a coil 690 (e.g., an inductive or capacitive coil) that can wirelessly transfer power to a corresponding coil 695 of an energy consuming device 675G.
[0050] In one embodiment, the energy consuming device 675F in
[0051] It should be recognized that
[0052] For ease of explanation, embodiments have been described in connection with the use of a single energy collection and storage device. It should be recognized, however, that due to its size, a person can easily carry and use multiple energy collection and storage devices. For example, a wallet or pocketbook having compartments sized for credit cards, identification cards, driver's licenses, etc., can be used to carry multiple energy collection and storage devices.
[0053] The disclosed embodiments provide a system and method for an energy collection and storage device. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
[0054] Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
[0055] This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.