Method of forming a card with embedded IC and electrochemical cell
View Patent ↗An IC card includes at least one plastic layer, a battery and at least one electronic device embedded in the plastic layer. The battery is electrically connected to the electronic device for providing power to the device. The battery includes an anode, a cathode, and at least one polymer matrix electrolyte (PME) separator disposed between the anode and the cathode. The PME separator includes a polyimide, at least one lithium salt and at least one solvent all intermixed. The PME is substantially optically clear and stable against high temperature and pressure, such as processing conditions typically used in hot lamination processing or injection molding.
1. A method of forming a card including embedded electronics, comprising the steps of:
providing a battery including an anode, a cathode, and at least one polymer matrix electrolyte (PME) separator disposed between said anode and said cathode, and
embedding said battery and at least one electronic comprising device in at least one plastic layer, said battery electrically connected to said electronic comprising device,
wherein said embedding process comprises:
a lamination process, wherein a temperature of at least 110° C. for at least 5 minutes under a pressure of at least 200 psi is used for said lamination process; and
wherein said battery provides a shift in open circuit voltage and capacity of less than 10% following said embedding process;
wherein the PME separator comprises a polyimide which is soluble indefinitely in N-methylpyrrolidone at 20% by weight, at least one lithium salt and at least one solvent intermixed; and
wherein the PME separator is substantially optically clear.
2. The method of claim 1 , wherein said lithium salt is in a concentration of at least 0.5 moles of lithium per mole of imide ring provided by said polyimide.
3. The method of claim 1 , wherein a temperature of at least 130° C. for at least 10 minutes under a pressure of at least 230 psi is used for said lamination process.
4. The method of claim 1 , wherein said anode comprises lithium ion intercalation material or lithium metal.
5. The method of claim 1 , wherein said cathode comprises an ion conducting polymeric binder intermixed with an intercalation material.
6. The method of claim 5 , wherein said polymeric binder comprises at least one polyimide.
7. The method of claim 1 , wherein said battery is formed by laminating only two layers, a first layer being said PME disposed on said cathode and a second layer being said anode.
8. The method of claim 1 , wherein a repeat unit weight per imide ring of said polyimide is no more than 350, no more than 300 or no more than 250.
9. The method of claim 1 , wherein the Li salt is at least one selected from the group consisting of LiCl, LiBr, LiI, LiClO 4 , LiBF 4 , LiAsF 6 , LiPF 6 , LiCF 3 SO 3 , LiBOB and LiN(CF 3 SO 2 ) 2 .
10. The method of claim 1 , wherein the battery is a bicell battery.
11. The method of claim 1 , wherein the battery is a packaged battery further comprising an exterior binder adhesive disposed between the packaged battery and the plastic layer to bind the packaged battery to the plastic layer and wherein the exterior binder adhesive is activated at a temperature of at least 100° C.
12. The method of claim 11 , wherein an interior binder adhesive seals said battery, wherein the interior binder adhesive has an activation temperature which is lower than an activation temperature of the exterior binder adhesive.
13. The method of claim 11 , wherein the packaged battery is disposed within an opening of a frame which can accommodate said battery.
14. The method of claim 1 , wherein the polyimide is selected from the group consisting of:
poly(PMDA/6FDA+TMMDA)imide;
poly(PMDA/PSDA+TMMDA)imide;
poly(BPDA+durene)imide;
poly(6FDA+durene)imide;
poly(PSDA+TMMDA)imide;
poly(6FDA+TMMDA)imide;
poly(BPDA+4,4′-fluorilidenediamiline);
poly(PMDA+TMMDA/TMPDA)imide;
poly(PMDA+4-isopropyl-m-phenylenediamine)imide; and
poly(PMDA+TMMDA/DAMs)imide.
15. A method of forming a card including embedded electronics, comprising the steps of:
providing a battery including an anode, a cathode, and at least one polymer matrix electrolyte (PME) separator disposed between said anode and said cathode, and
embedding said battery and at least one electronic comprising device in at least one plastic layer, said battery electrically connected to said electronic comprising device,
wherein said embedding process comprises:
a lamination process, wherein a temperature of at least 110° C. for at least 5 minutes under a pressure of at least 200 psi is used for said lamination process; and
wherein said battery provides a shift in open circuit voltage and capacity of less than 10% following said embedding process;
wherein the PME separator comprises a polyimide which is soluble indefinitely in N-methylpyrrolidone at 20% by weight, at least one lithium salt and at least one solvent intermixed; and
wherein the polyimide is selected from the group consisting of:
poly(PMDA/6FDA+TMMDA)imide;
poly(PMDA/PSDA+TMMDA)imide;
poly(BPDA+durene)imide;
poly(6FDA+durene)imide;
poly(PSDA+TMMDA)imide;
poly(6FDA+TMMDA)imide;
poly(BPDA+4,4′-fluorilidenediamiline);
poly(PMDA+TMMDA/TMPDA)imide;
poly(PMDA+4-isopropyl-m-phenylenediamine)imide; and
poly(PMDA+TMMDA/DAMs)imide.
16. The method of claim 15 , wherein said lithium salt is in a concentration of at least 0.5 moles of lithium per mole of imide ring provided by said polyimide.
17. The method of claim 15 , wherein a temperature of at least 130° C. for at least 10 minutes under a pressure of at least 230 psi is used for said lamination process.
18. The method of claim 15 , wherein said anode comprises lithium ion intercalation material or lithium metal.
19. The method of claim 15 , wherein said cathode comprises an ion conducting polymeric binder intermixed with an intercalation material.
20. The method of claim 15 , wherein said polymeric binder comprises at least one polyimide.
21. The method of claim 15 , wherein said battery is formed by laminating only two layers, a first layer being said PME disposed on said cathode and a second layer being said anode.
22. The method of claim 15 , wherein a repeat unit weight per imide ring of said polyimide is no more than 350, no more than 300 or no more than 250.
23. The method of claim 15 wherein the Li salt is at least one selected from the group consisting of LiCl, LiBr, LiI, LiClO 4 , LiBF 4 , LiAsF 6 , LiPF 6 , LiCF 3 SO 3 , LiBOB and LiN(CF 3 SO 2 ) 2 .
24. The method of claim 15 , wherein the battery is a bicell battery.
25. The method of claim 15 , wherein the battery is a packaged battery further comprising an exterior binder adhesive disposed between the packaged battery and the plastic layer to bind the packaged battery to the plastic layer and wherein the exterior binder adhesive is activated at a temperature of at least 100° C.
26. The method of claim 25 , wherein an interior binder adhesive seals said battery, wherein the interior binder adhesive has an activation temperature which is lower than an activation temperature of the exterior binder adhesive.
27. The method of claim 25 , wherein the packaged battery is disposed within an opening of a frame which can accommodate said battery.