Battery arrays, constructions and method

Abstract

Disclosed is a stacked array of a plurality of thin film batteries that are electrically connected together. The stacked array is in a staggered configuration. The outermost points of side edges on one side of the stacked array preferably generally conform to an interior surface of an electronic device or component thereof in order to advantageously save space in the device. In an embodiment, the stacked array comprises at least one battery having a single surface in contact with a plurality of batteries. In another embodiment, a shaped array of a plurality of thin film batteries electrically connected together is provided, whereby a plurality of batteries are arranged in a single layer on a non-rectangular substrate adjacent to one another generally in the shape of the surface of the substrate. Additionally, a thin film battery is described wherein at least one via is provided through the substrate and at least one other via through an insulation layer to provide electronic connection to the battery cell.

1 . A stacked array of a plurality of thin film batteries electrically connected together, wherein the stacked array is in a staggered configuration. 
     
     
         2 . The stacked array of  claim 1  wherein outermost points of side edges on one side of the stacked array define a boundary line and wherein the boundary line is a substantially straight line. 
     
     
         3 . The stacked array of  claim 1  outermost points of side edges on one side of the stacked array define a boundary line and wherein the boundary line is not a straight line. 
     
     
         4 . The stacked array of  claim 1  in a battery compartment, wherein the stacked array conforms to at least two adjacent inner surfaces of the interior of the battery compartment. 
     
     
         5 . An intermediate battery component comprising the stacked array in the battery compartment of  claim 4 . 
     
     
         6 . The intermediate battery component of  claim 5 , the intermediate battery component comprising an integrated circuit. 
     
     
         7 . An electronic device comprising the comprising the stacked array in the battery compartment of  claim 4 . 
     
     
         8 . An electronic device comprising the intermediate battery component of  claim 5 . 
     
     
         9 . The stacked array of  claim 1 , wherein the stacked array defines a three dimensional volume that is selected from a pyramid shape, a truncated pyramid, a conical shape, a truncated conical shape, a rhomboid, a spherical shape and a truncated spherical shape, an ellipsoid shape and a truncated ellipsoid shape, or an oblique shape that is preferably an oblique cylinder or an oblique hexahedron. 
     
     
         10 . A method of providing power to an electronic device using a plurality of thin film batteries including:
 stacking the plurality of thin films batteries in a staggered configuration to form a stacked array;   placing the stacked array in an electronic device or component thereof so that the outermost points of side edges on one side of the stacked array generally conform to an interior surface of the electronic device or component thereof; and   before or after placing the stacked array in an electronic device or component thereof, electrically connecting the plurality of thin film batteries.   
     
     
         11 . The method of  claim 10  wherein the interior surface is a planar surface. 
     
     
         12 . The method of  claim 10  wherein the interior surface is a curved surface. 
     
     
         13 . A shaped array of a plurality of thin film batteries electrically connected together, whereby a plurality of batteries are arranged in a single layer on a non-rectangular substrate adjacent to one another generally in the shape of the surface of the substrate. 
     
     
         14 . The shaped array of  claim 13 , wherein the batteries are of uniform size and shape. 
     
     
         15 . The shaped array of  claim 13 , wherein the batteries are rectangular in shape. 
     
     
         16 . The shaped array of  claim 13 , wherein the batteries are in a shape selected from rectangular or triangular. 
     
     
         17 . The shaped array of  claim 13 , wherein the substrate surface is in the shape selected from the shape of a triangle, the shape of a circle or wherein the substrate surface comprises an annular hole. 
     
     
         18 . The stacked array of  claim 1 , wherein the stacked array comprises at least one battery having a single surface in contact with a plurality of batteries. 
     
     
         19 . A thin film battery comprising
 a) a substrate having a first surface;   b) a first current collector on the first surface of the substrate;   c) a second current collector, wherein one of the first and second current collector is an anode current collector and the other is a cathode current collector;   d) an electrolyte layer, the electrolyte separating the cathode current collector from the anode current collector;   f) an insulation layer, the insulation layer together with the electrolyte layer separating the anode current collector from the cathode current collector;   wherein the first current collector is exposed to provide connectivity for electrical connection to a device to be powered by the battery through at least one via in the substrate, and   wherein the second current collector is exposed to provide connectivity for electrical connection to a device to be powered by the battery through at least one via in the insulation layer.   
     
     
         20 . The thin film battery of  claim 19 , wherein either and/or both the substrate and the insulation layer contain two or more vias.