Methods for making device enclosures and devices with an integrated battery

Abstract

An electrically powered device includes a shell, and a battery integrated with the shell. The electrically powered device also includes a trace, and a site adapted to receive an electrically powered component, wherein the battery, the trace and the electrically powered component form a portion of a circuit. The electrically shell may be a portion of an enclosure. The battery is formed within the shell and may be comprised of one or a plurality of deposited layers.

1 . A method to fabricate a device, the method comprising: 
 providing a first substrate that will form a portion of a shell enclosure for an electrically powered apparatus;    depositing a first conductive layer on a first surface area of the first substrate;    fabricating a thin-film battery by depositing a cathode film in electrical contact with the first conductive layer; depositing an anode film in electrical contact with a second conductive layer; and forming an electrolyte layer in contact with and completely separating the anode film and the cathode film; and    forming the first substrate into a shape having a concave interior surface and a convex exterior surface and configured to be the portion of the shell enclosure.    
     
     
         2 . The method of  claim 1 , wherein the providing of the first substrate, the depositing of the first conductive layer, the fabricating of the battery and the forming of the first substrate are performed in the order indicated.  
     
     
         3 . The method of  claim 1 , wherein the providing of the first substrate further includes depositing the second conductive layer on a second surface area of the first substrate.  
     
     
         4 . The method of  claim 3 , further comprising folding the first substrate upon itself.  
     
     
         5 . The method of  claim 1 , wherein the depositing of the cathode film includes depositing a lithium intercalation material.  
     
     
         6 . The method of  claim 1 , wherein the depositing of the anode film includes depositing a lithium intercalation material and the depositing of the cathode film includes depositing a lithium intercalation material.  
     
     
         7 . The method of  claim 1 , wherein the depositing of the anode film includes depositing a lithium intercalation material.  
     
     
         8 . The method of  claim 1 , wherein the depositing of the anode film includes depositing lithium metal.  
     
     
         9 . The method of  claim 1 , wherein the fabricating of the battery comprises depositing a lithium phosphorus oxynitride as at least part of the electrolyte layer, wherein the electrolyte layer is in contact with and completely separates the anode film and the cathode film, and wherein the cathode film includes an intercalation material.  
     
     
         10 . The method of  claim 1 , wherein the fabricating of the battery further comprises fabricating the battery on the first shell after the forming of the substrate into the shape of the shell enclosure.  
     
     
         11 . The method of  claim 10 , wherein the fabricating of the battery further comprises fabricating the battery on the interior surface.  
     
     
         12 . The method of  claim 10 , wherein the fabricating of the battery further comprises sputtering the battery on the exterior surface.  
     
     
         13 . The method of  claim 1 , wherein the fabricating of the battery further comprises placing a protective layer over the battery.  
     
     
         14 . The method of  claim 1 , further comprising: 
 forming a trace;    forming a site adapted to receive an electrically powered component; and    connecting the battery, the trace, and the electrically powered component into at least a portion of a circuit.    
     
     
         15 . The method of  claim 1 , wherein the forming includes rolling the first substrate to form the shell.  
     
     
         16 . A method to fabricate a device, the method comprising: 
 providing a first substrate that will form a portion of a rolled apparatus enclosure for an electrically powered apparatus;    depositing a first conductive layer on a first surface area of the first substrate;    fabricating a battery by depositing a cathode film in electrical contact with the first conductive layer; depositing an anode film in electrical contact with a second conductive layer; and    forming an electrolyte layer in contact with and completely separating the anode film and the cathode film; and    rolling the first substrate into a shape configured to be the portion of the rolled apparatus enclosure.    
     
     
         17 . The method of  claim 16 , wherein the rolling the first substrate further includes rolling the first substrate upon itself.  
     
     
         18 . The method of  claim 16 , wherein the rolling the first substrate further includes rolling the first substrate around an electrical motor that is electrically coupled to the battery and wherein the electrical motor includes a shaft operatively coupled to the motor and a chuck placed upon the shaft to form a hand-held drill for homeowner use.  
     
     
         19 . The method of  claim 16 , wherein the rolling the first substrate further includes rolling the first substrate and coupling an LED light to the battery to form a flashlight.  
     
     
         20 . A method to fabricate a device, the method comprising: 
 providing a substrate that will form a portion of a shell enclosure for an electrically powered apparatus;    depositing a first conductive layer on a first surface area of the substrate and a second conductive layer on a second surface area of the substrate;    fabricating a battery by depositing a cathode film in electrical contact with the first conductive layer; depositing an anode film in electrical contact with the second conductive layer; and forming an electrolyte layer in contact with and completely separating the anode film and the cathode film, wherein the electrolyte layer includes LiPON; and    forming the substrate into a shape having a concave interior surface and a convex exterior surface and configured to be the portion of the shell enclosure.    
     
     
         21 . The method of  claim 20 , wherein the providing of the substrate, the depositing of the first conductive layer, the fabricating of the battery and the forming of the substrate are performed in the order indicated.  
     
     
         22 . The method of  claim 20 , further comprising folding the substrate upon itself.  
     
     
         23 . The method of  claim 20 , wherein the providing of the substrate, the depositing of the first conductive layer, the fabricating of the battery and the rolling of the substrate are performed in the order indicated.  
     
     
         24 . The method of  claim 20 , wherein the depositing of the cathode film includes depositing a lithium intercalation material.