Energy storage device

• US 10,199,165 B2
• Filed: 12/17/2014
• Issued: 02/05/2019
• Est. Priority Date: 08/30/2012
• Status: Active Grant

• Current Assignee: Carver Scientific Inc.
• Original Assignee: Carver Scientific Inc.
• Inventors: Carver, David Reginald, Carver, Robert Glenn, Fulfer, Bradford Wesley, Gibbs, Jaime Hayes, Hall, Sean Claudius, Priddy, Aaron Trent, Reynolds, Sean William
• Primary Examiner(s): Orlando, Michael N
• Assistant Examiner(s): Bradford, Elizabeth
• Application Number:
  US14/574,175
• Publication Number:
  US 20150131198A1
• Time in Patent Office: 1,511 Days
• Field of Search: 1562755
• CPC Class Codes: C08F 232/06 having two or more carbon-to-carbon double bonds
• CPC Class Codes: H01G 4/018 Dielectrics
• CPC Class Codes: H01G 4/14 Organic dielectrics
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing

Abstract

Embodiments of a high-permittivity, low-leakage energy storage device, such as a capacitor, and methods of making the energy storage device are disclosed. The disclosed device includes electrically conductive first and second electrodes, and a sterically constrained dielectric film disposed between the first and second electrodes. The sterically constrained dielectric film comprises a plurality of polymeric molecules, and at least some of the polymeric molecules are bound to the first electrode. The disclosed device may include an insulative layer between the first electrode and the dielectric film and/or between the second electrode and the dielectric film.

Claims

1. An energy storage device, comprising:

an electrically conductive first electrode;

an electrically conductive second electrode;

a sterically constrained dielectric film disposed between the electrically conductive first and second electrodes, the sterically constrained dielectric film comprising a plurality of polymeric molecules having one or more polar functional groups, ionizable functional groups, or a combination thereof, the energy storage device having an energy storage capacity, in the absence of the energy storage device having been charged and/or discharged, of at least 1 Wh/kg based solely on the weight of the sterically constrained dielectric film disposed between the electrically conductive first and second electrodes; and

a first insulative layer disposed between the electrically conductive first electrode and the dielectric film and a second insulative layer disposed between the electrically conductive second electrode and the sterically constrained dielectric film, wherein each of the first insulative layer and the second insulative layer consists of a polymerized p-xylylene insulative layer or a copolymer insulative layer prepared from p-xylene and one or more co-monomers selected from acrylates, methacrylates, a-pinene, R-(−

)carvone, linalool, cyclohexene, dipentene, a-terpinene, R-(+)-limonene, or any combination thereof,

wherein the electrically conductive first electrode and the first insulative layer collectively form a composite first electrode,

the electrically conductive second electrode and the second insulative layer collectively form a composite second electrode, and

at least 1% of the plurality of polymeric molecules are bound to the first insulative layer of the composite first electrode, thereby sterically constraining the dielectric film.

2. The energy storage device of claim 1, wherein the polymeric molecules are protein molecules.

3. The energy storage device of claim 1, wherein the energy storage device has an energy storage capacity at least 100×

greater than an energy storage capacity of a comparable energy storage device comprising a dielectric film having substantially the same chemical composition as the dielectric film of the energy storage device, but wherein the polymeric molecules are not bound to the composite first electrode.

4. The energy storage device of claim 1, wherein the sterically constrained dielectric film has a permittivity from 50% to 10,000,000% greater than a permittivity of a dielectric film comprising the plurality of polymeric molecules having one or more polar functional groups, ionizable functional groups, or a combination thereof, wherein the polymeric molecules are not bound to the composite first electrode.

5. The energy storage device of claim 1, wherein polymeric molecules are bound to at least 1% of a surface of the first insulative layer in contact with the dielectric film.

6. The energy storage device of claim 1, wherein the first insulative layer and the second insulative layer independently have an average thickness of from 5 nm to 10 μ

m.

7. The energy storage device of claim 6, wherein the first insulative layer and the second insulative layer are polymerized p-xylylene insulative layers.

8. The energy storage device of claim 1, wherein at least 25% of the plurality of polymeric molecules are bound to the first insulative layer.

9. A method for making an energy storage device according to claim 1, the method comprising:

making an energy storage device by

applying a first insulative layer to an electrically conductive first electrode to form a composite first electrode, wherein the first insulative layer consists of a polymerized p-xylylene insulative layer or a copolymer insulative layer prepared from p-xylene and one or more comonomers selected from acrylates, methacrylates, a-pinene, R-(−

)carvone, linalool, cyclohexene, dipentene, a-terpinene, R-(+)-limonene, or any combination thereof;

applying a dielectric film to the first insulative layer of the composite first electrode, the dielectric film comprising a material that (i) is electrically insulative and/or exhibits a high permittivity and (ii) comprises a plurality of polymeric molecules having one or more polar functional groups, ionizable functional groups, or a combination thereof;

contacting the dielectric film with a composite second electrode comprising a second insulative layer and positioned such that the second insulative layer of the composite second electrode contacts the dielectric film, wherein the second insulative layer consists of a polymerized p-xylylene insulative layer or a copolymer insulative layer prepared from p-xylene and one or more co-monomers selected from acrylates, methacrylates a-pinene, R-(−

)carvone, linalool, cyclohexene, dipentene, a-terpinene, R-(+)-limonene, or any combination thereof; and

binding at least 1% of the plurality of polymeric molecules to the composite first electrode to form a sterically constrained dielectric film by

(i) applying an electric field across the composite first electrode, the dielectric film, and the composite second electrode such that the composite first electrode is a positive electrode, the electric field being applied for an effective period of time to bind at least 1% of the plurality of polymeric molecules to the first insulative layer of the composite first electrode,

(ii) treating the dielectric film with a chemical agent, or

(iii) a combination thereof, thereby making the energy storage device.

10. The method of claim 9, wherein the electric field is at least 0.001 V/μ

m based on an average thickness of the dielectric film.

11. The method of claim 10, wherein the electric field is 0.005-1 V/μ

m and the effective period of time is from 1 second to 30 minutes.

12. The method of claim 9, wherein the first insulative layer is a polymerized p-xylylene insulative layer.

13. The method of claim 9, wherein treating the dielectric film with a chemical agent comprises:

applying a radical initiator to the first insulative layer before applying the dielectric film to the first insulative layer; and

activating the radical initiator after applying the dielectric film to the first insulative layer, thereby binding at least some of the polymeric molecules to the first insulative layer of the composite first electrode.

14. The method of claim 9, wherein treating the dielectric film with a chemical agent comprises:

(i) derivatizing the polymeric molecules with a derivatization agent to provide functional groups capable of cross-linking to the first insulative layer of the composite first electrode;

(ii) including a crosslinking agent in the film material of the dielectric film;

(iii) including a radical initiator in the film material of the dielectric film, and activating the radical initiator after applying the dielectric film to the first insulative layer;

(iv) applying a radical initiator to the first insulative layer before applying the dielectric film to the first insulative layer, and activating the radical initiator after applying the dielectric film to the first insulative layer;

(v) applying a plasma to the first insulative layer before applying the dielectric film to the first insulative layer;

or

(vi) any combination thereof.

15. The method of claim 9, wherein the polymeric molecules comprise proteins, parylene, acrylic acid polymers, methacrylic acid polymers, polyethylene glycol, urethane polymers, epoxy polymers, silicone polymers, terpenoid polymers, naturally occurring resin polymers, polyisocyanates, or combinations thereof.

16. The method of claim 9, wherein the polymeric molecules comprise proteins or derivatized proteins.

17. The method of claim 9, wherein applying the dielectric film to the composite first electrode comprises:

forming the dielectric film on a removable carrier film;

removing the removable carrier film; and

applying the dielectric film to the first insulative layer of the composite first electrode.

18. The method of claim 9, wherein the polymeric molecules are formed in situ, the method further comprising:

applying a composition comprising a crosslinking agent and a plurality of polymeric molecule precursors comprising one or more polar functional groups, ionizable functional groups, or a combination thereof to the first electrode; and

activating the crosslinking agent, thereby crosslinking the polymeric molecule precursors to provide a dielectric film comprising a plurality of polymeric molecules.

19. The method of claim 18, wherein the polymeric molecule precursors comprise (i) amino acid molecules, (ii) oligopeptides, (iii) polypeptides, or (iv) a combination thereof.

20. The method of claim 18, wherein the polymeric molecule precursors further comprise p-xylylene monomers.