Abstract:
A system that powers a wireless sensor mechanism from ambient sources without the need to replace a battery is disclosed. The present invention uses an energy harvesting mechanism built onto, for example, a substrate to recharge a rechargeable energy storage mechanism that is built on the same substrate. The energy storage mechanism provides power to a transmission/receiving mechanism and microprocessor that may also be arranged on said substrate. The energy-harvesting mechanism may be combined with a power management unit to enable efficient use and regulation of the harvested energy.

Description:
RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 61/103,746, entitled “Environmentally-Powered Wireless Sensor Module,” filed on Oct. 8, 2008, which is incorporated herein by reference in its entirety. 
         [0002]    This application is related to U.S. patent application Ser. No. 11/561,277, entitled “Hybrid Thin-Film Battery,” filed on Nov. 17, 2006, U.S. patent application Ser. No. 11/687,032, entitled “Metal Film Encapsulation,” filed on Mar. 16, 2007, U.S. patent application Ser. No. 11/748,471, entitled “Thin Film Battery on an Integrated Circuit or Circuit Board and Method Thereof,” filed on May 14, 2007, U.S. Patent Application Ser. No. 61/087,927, entitled “Energy Device with Integral Collector Surface for Electromagnetic Energy Harvesting and Method Thereof,” filed on Aug. 11, 2008, and U.S. Patent Application Ser. No. 61/096,415, entitled “Energy Device with Integral Collector Surface for Electromagnetic Energy Harvesting and Method Thereof,” filed on Sep. 12, 2008, which are incorporated herein by reference in their entirety. 
     
    
     TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
       [0003]    This invention relates to an apparatus, method, and system for communicating data. More particularly, this invention relates to a device capable of being incorporated on a substrate and may be powered by harvesting energy from any ambient source, such as, for example, radio frequency, solar power, wind, vibration or human activity which may be stored and/or converted to communication signals to transmit information. 
         [0004]    As electronics have become smaller and more durable, there has been a continuous progression towards using electrical devices in ways never before thought possible. The energy source used to operate these devices may typically be a battery, which can be embedded within the electronics and configured for a single use, configured to be replaceable, or configured to be rechargeable. Each of these current options have shortcomings, as an embedded battery may render associated electronics useless once the battery is discharged or damaged, replaceable batteries require additional space and material to house, and an externally rechargeable battery requires additional material for a connecting plug and a battery charger. Each of these options is typically not ideal, as applications tend to demand equipment that can be lighter, without additional power cords and usable during times when access to an electrical wall outlet or other external power source is unavailable. 
         [0005]    Thus, a demand exists to have an electronic device that does not require large batteries and may be able to generate its own energy. 
         [0006]    As the ability, desire, and reality of global travel has become more commonplace, consumers often find themselves in need of portable electronic devices. Powering these devices may be a challenge, however, as there are many different voltages and frequencies of electricity power supplies in different countries. Electrical wall outlets are typically needed to charge many consumer devices ranging from electric shavers to computers, cell phones, and other devices that may send or receive signals. 
         [0007]    Thus, a demand exists to have an electronic device that may be capable of operating without the use of an electrical wall outlet. 
       SUMMARY OF INVENTION 
       [0008]    Ambient energy exists in many forms and in abundant quantity, providing an opportunity to put that energy to a beneficial electrical use with the assistance of an energy harvesting device. The energy harvester may include, for example, a device that converts specific types of ambient energy into electrical energy, which can then be stored in an electrical energy storage device such as a battery or capacitor. Depending on the application, harvested energy may, for example, be used instantaneously or stored in a component such as a battery and used at defined time intervals or when requested by a remote device. 
         [0009]    It is one object of certain exemplary embodiments of this invention to use an energy harvester, such as, for example, a piezoelectric mechanism, and connect it to or incorporate it onto a substrate to harvest energy from one or more non-conventional sources and use that energy to recharge a device such as a battery that may be located such that it, for example, is an integral and inseparable part of a substrate. 
         [0010]    The present invention may include, for example, a unique arrangement of a microcontroller, a signal transmitter, a signal receiver, an energy storage device and an energy harvester. In some embodiments, the energy harvester may be a piezoelectric sensor that converts motion/vibration energy into electric energy, wherein the converted energy may be used to recharge a battery, thereby providing power to a signal receiver/transmitter. The signal receiver/transmitter may be, for example, a ZigBee transceiver. In other embodiments, the piezoelectric mechanism may perform a dual function as a converter of motion energy to electrical energy and also a pedometer. 
         [0011]    Certain embodiments of the present invention are also included in a system having a transmitter for transmitting a message to an external receiver. The system may also have one or more sensors that may be monitored by a microcontroller. Certain signals from the sensors may be processed by the microcontroller and the processed information may be transmitted to a receiver that may be located remotely. 
         [0012]    In some embodiments of the invention, the device may receive a signal from one or more GPS satellites to determine the geographical location of said device. 
         [0013]    For improved performance in this application, also disclosed is an example of a manufacturing process for a thin-film battery having a heat and pressure-resilient separation layer for incorporating the battery cell onto a substrate. 
     
    
     
       BRIEF DESCRIPTION OF DRAWING 
         [0014]    Some features and advantages of the invention are described with reference to the drawing of a certain preferred embodiment, which is intended to illustrate and not to limit the invention. 
           [0015]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention that together with the description serve to explain the principles of the invention: 
           [0016]      FIG. 1  is a diagram of an embodiment of the present invention showing the subcomponents of the device. 
           [0017]      FIG. 2  is a diagram of an embodiment of the present invention showing the step-by-step construction of an embodiment of one contemplated device. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0018]    It is to be understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements, and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps or subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise. 
         [0019]    Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices and materials are described although any methods, techniques, devices, or materials similar or equivalent to those described may be used in the practice or testing of the present invention. Structures described herein are to be understood also to refer to functional equivalents of such structures. 
         [0020]    All patents and other publications are incorporated herein by reference for the purpose of describing and disclosing, for example, the methodologies described in such publications that might be useful in connection with the present invention. These publications are provided solely for their disclosure prior to the filing date of the present application. Nothing in this regard should be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention or for any other reason. 
         [0021]      FIG. 1  shows the detailed process occurring within the present invention. The energy  110 , which may result from radio frequency, solar power, wind power, vibration, human activity such as walking or jogging, water movement, temperature variations and rotational movements reaches an energy harvesting mechanism  120  and may be converted into a usable and storable form of energy, such as, for example, electricity. The energy harvesting mechanism  120  uses the harvested energy to recharge a rechargeable energy storage device  130 . In some embodiments, the process of energy harvesting and recharging an energy storage device may be performed under the monitoring and regulation of, for example, a power management unit  130 . The energy storage device  130  may store the energy and, when needed, power the microcontroller  150  and the transmitter and/or receiver  140  depending on whether a signal is being sent out, received, or both. The transmitter and/or receiver  140  may be, for example, a ZigBee transceiver. The transceiver may be part of a wireless mesh network, which is one of the possible implementations of a Zigbee network. Independent nodes in a mesh may provide self repairing features if a failure at one of the nodes is discovered. Therefore, mesh nodes relying on energy harvesting may be more robust over the long run, being able to “hibernate” during extended periods when the energy source is not available. A sensor  160  may be used to measure any desirable physical quantities depending on the use of the device. 
         [0022]      FIG. 2  shows an example of the steps that may be used to construct some embodiments of the present invention on a substrate, such as, for example, a thin, flexible substrate. Step  200  shows the beginning of the construction where an energy storage device, shown in this example as a thin-film battery, as the foundation. Step  210  shows attaching a substrate to the energy storage device. Step  220  may be performed to add a transmitter/receiver mechanism to the substrate. Step  230  may be performed to add a microcontroller onto the substrate and connecting it to the transmitter/receiver mechanism. Step  240  may be performed to add an energy harvesting mechanism and power management unit to the substrate. 
         [0023]    In some embodiments, the substrate may be rigid or semi-rigid. In several embodiments, the substrate may be a thin, flexible substrate. The substrate may be embedded internally, laminated, glued or mechanically attached with screws or otherwise for installation onto the surface of a target application. 
         [0024]    In several embodiments, the energy harvesting mechanism is based on a piezoelectric transducer. This embodiment may be used by taking applied mechanical stress or pressure and transforming it into electrical energy to recharge or be stored in an energy storage device. In other embodiments, the energy harvesting mechanism is based on a radio frequency energy transducer. In some embodiments, the energy harvesting mechanism may also be a device that can convert solar power, wind power, vibration, pedestrian activity such as walking or jogging, water movement, temperature variations or rotational movements into usable energy such as electricity. 
         [0025]    In addition to an electrochemical storage device, such as a battery or thin-film battery, the energy storage component may be an electrical storage device such as a capacitor or thin-film capacitor, but may also be a mechanical energy storage device, such as, for example, a flywheel, micro-flywheel, micro electro-mechanical system (MEMS), or a mechanical spring. In several embodiments, the thin-film battery may contain a metallic lithium anode. In some embodiments, the thin-film battery may not contain a metallic lithium anode but may instead contain a Li-ion anode or a Li-free anode. The energy storage component may also be an electro-mechanical device, such as a piezoelectric element or a magneto-electric element, similar to the invention disclosed in U.S. Pat. No. 7,088,031, entitled “Method and Apparatus for an Ambient Energy Battery or Capacitor Recharge System” which is herein incorporated by reference in its entirety. The energy storage component may also be a thermal energy storage device, such as a thermal mass container, or it could be a chemical energy storage device, such as, for example, a hydrogen generator with hydrogen container or an ozone generator with ozone container. Each one of these devices may be used to store energy based on exemplary elements of the system. 
         [0026]    In some embodiments, the system on the substrate contains a receiver that may receive a signal from one or more GPS satellites to determine the geographic location and direction of the device, as well as the speed of the device if the device happens to be in motion. 
         [0027]    In some embodiments, one or more sensors may measure any number of different physical qualities. In some embodiments, one sensor may be measuring the weather in which case it may be, for example, a thermometer to measure the temperature, a hydrometer to measure the humidity, an anemometer to measure the velocity or pressure of the wind or a barometer to measure the atmospheric pressure. A barometer in combination with a microprocessor may be able to detect changes in pressure and predict changes in the weather. In several embodiments, one sensor may be used to measure pressure and determine changes in altitude. 
         [0028]    In some embodiments where the energy storage device is a thin-film battery, the thin-film battery may have a thickness that does not exceed 1 cm and a lateral area that may be less than 10 square inches. In another embodiment, the lateral area of said thin-film battery may be less than 0.25 square centimeters. 
         [0029]    In a different embodiment, the thin-film battery may have a heat and pressure-resilient separation layer for purposes of incorporating the battery cell into the substrate manufacturing process. 
         [0030]    In the several embodiments in which the energy storage device is a rechargeable device, such as, for example, a thin-film battery, this will present an opportunity whereby the present invention may be capable of performing nearly indefinitely. The present invention may, for example, allow for energy created through radio frequency, wind power, solar power, vibration, human activity, water movement, temperature variations and rotational movements to be harvested in an energy harvesting mechanism and for that harvested energy to ensure that the rechargeable energy storage device may be so charged. 
         [0031]    This invention has been described herein in several embodiments. It is evident that there are many alternatives and variations that can embrace the performance of ceramics enhanced by the present invention in its various embodiments without departing from the intended spirit and scope thereof. The embodiments described above are exemplary only. One skilled in the art may recognize variations from the embodiments specifically described here, which are intended to be within the scope of this disclosure. As such, the invention is limited only by the following claims. Thus is intended that the present invention cover the modifications of this invention provided they come within the scope of the appended claims and their equivalents.