Electrode for Hybrid Energy Storage Device and Method of Making Same

• US 20090035657A1
• Filed: 10/19/2007
• Published: 02/05/2009
• Est. Priority Date: 10/23/2006
• Status: Abandoned Application

• Current Assignee: Axion Power International, Inc
• Original Assignee: Axion Power International, Inc
• Inventors: Buiel, Edward R., Rabinovich, Leonid, Sun, Wei, Swiecki, Adam J., Eshkenazi, Victor, Vichnyakov, Vladimir
• Application Number:
  US11/875,108
• Publication Number:
  US 20090035657A1
• Time in Patent Office: Days
• US Class Current: 429/211
• CPC Class Codes: H01G 11/04 Hybrid capacitors
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/46 Metal oxides
• CPC Class Codes: H01G 11/68 characterised by their material
• CPC Class Codes: H01M 4/14 Electrodes for lead-acid accumulators
• CPC Class Codes: H01M 4/56 of lead
• CPC Class Codes: H01M 4/68 for use in lead-acid accumulators
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

An electrode for a hybrid energy storage device includes a current collector; an active material adhered to and in electrical contact with at least one surface of the current collector; and a tab element, wherein the thickness of the tab element is greater than the thickness of the current collector.

Claims

1. An electrode for a hybrid energy storage device, comprising:

a current collector;

a tab element extending from a side of the electrode, wherein the thickness of the tab element is greater than the thickness of the current collector; and

an active material adhered to and in electrical contact with at least one surface of the current collector.

2. The electrode according to claim 1, wherein the electrode comprises a negative electrode and the current collector comprises copper or copper alloy.

3. The electrode according to claim 2, wherein the active material comprises activated carbon.

4. The electrode according to claim 2, wherein the tab element comprises copper.

5. The electrode according to claim 2, wherein the tab element comprises steel.

6. The electrode according to claim 1, wherein the thickness of the tab element is about 0.1 mm to about 10 mm.

7. The electrode according to claim 6, wherein the thickness of the current collector is about 75 microns to about 0.5 mm.

8. An electrode according to claim 1, wherein the electrode comprises a positive electrode and the current collector comprises lead and the active material comprises lead oxide.

9. A method of making an electrode for a hybrid energy storage device, comprising:

cutting a current collector from a first sheet or roll of conductive material, wherein a height of the current collector equals the width of the first sheet or roll and wherein a width of the current collector equals the length cut from the first sheet or roll;

cutting at least one strip from a second sheet or roll of material for a tab element, wherein a width of the second sheet or roll equals a width of the tab element;

positioning the at least one strip where the tab element is to be affixed; and

attaching the at least one strip to the current collector, thereby forming a tab element extending from a side of the current collector,

wherein the thickness of the tab element is greater than the thickness of the current collector.

10. A method according to claim 9, further comprising applying a corrosion-resistant conductive coating to at least one side of the current collector.

11. A method according to claim 9, further comprising applying an active material to at least one side of the current collector.

12. The method according to claim 9, further comprising folding the at least one strip over an edge of the current collector prior to said attaching.

13. The method according to claim 9, further comprising:

cutting two strips from the second sheet or roll;

positioning the two strips so that each strip is on an opposite side of the current collector; and

attaching the two strips to the current collector and to each other.

14. The method according to claim 9, wherein the electrode comprises a negative electrode and the current collector comprises copper or copper alloy.

15. The method according to claim 14, wherein the tab element comprises copper.

16. The method according to claim 14, wherein the tab element comprises steel.

17. The method according to claim 14, wherein the thickness of the tab element is about 0.1 mm to about 10 mm.

18. The method according to claim 17, wherein the thickness of the current collector is about 75 microns to about 0.5 mm.

19. The method according to claim 9, wherein the electrode comprises a positive electrode and the current collector comprises lead.