ENERGY STORAGE DEVICE AND METHOD OF MANUFACTURING THE SAME

• US 20120263978A1
• Filed: 04/12/2012
• Published: 10/18/2012
• Est. Priority Date: 04/14/2011
• Status: Abandoned Application

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: Wang, Chung-Hsiung, Liao, Wen-Hsiung, Lin, Chi-Feng, Chung, Han-Yang
• Application Number:
  US13/445,856
• Publication Number:
  US 20120263978A1
• Time in Patent Office: Days
• US Class Current: 429/7
• CPC Class Codes: H01G 11/74 Terminals, e.g. extensions of current collectors
• CPC Class Codes: H01G 11/82 Fixing or assembling a capacitive element in a housing, e.g. mounting electrodes, current collectors or terminals in containers or encapsulations
• CPC Class Codes: H01G 2/06 specially adapted for mounting on a printed-circuit support
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 50/105 Pouches or flexible bags
• CPC Class Codes: H01M 50/184 characterised by their shape or structure
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/191 Inorganic material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/43 Electric condenser making
• CPC Class Codes: Y10T 29/4911 including sealing

Abstract

An energy storage device and a method of manufacturing the same are disclosed. The energy storage device includes a circuit board, a conductive cover disposed above the circuit board, a sealing structure, a metal coating layer, and an electrochemical cell. The sealing structure is disposed between the circuit board and the circumference of the conductive cover such that the circuit board, the conductive cover, and the sealing structure together form a sealed space where the electrochemical cell is disposed. The metal coating layer continuously covers a part of the conductive cover, an exposed portion of the sealing structure, and a part of the circuit board. Therefore, even if the energy storage device needs to be heated during a product assembly, the metal coating layer can keep the sealing structure structurally stable, and the electrolyte of the electrochemical cell will not leak; the whole energy storage device therefore can keeps undamaged.

Claims

1. An energy storage device, comprising:

a circuit board comprising an insulation substrate and a first electrode circuit and a second electrode circuit formed on the insulation substrate;

a conductive cover having a circumference;

a sealing structure disposed between the circuit board and the circumference of the conductive cover such that the circuit board, the conductive cover, and the sealing structure together form a sealed space;

a metal coating layer successively covering a portion of the conductive cover, an exposed portion of the sealing structure, and a portion of the circuit board; and

an electrochemical cell disposed in the sealed space and electrically connected to the first electrode circuit and the second electrode circuit respectively.

2. The energy storage device of claim 1, wherein the sealing structure comprises a welding metal portion and is provided in a ring structure, and a welding temperature of the welding metal portion is lower than a reflow temperature for the energy storage device.

3. The energy storage device of claim 2, wherein the sealing structure further comprises an adhesive portion, the welding metal portion and the adhesive portion respectively are disposed in circle, and the adhesive portion is at an inner side of the welding metal portion.

4. The energy storage device of claim 2, wherein the welding metal portion is of an alloy of Sn—

Ag—

Cu, and the metal coating layer is of Cu.

5. The energy storage device of claim 1, wherein the circuit board comprises an insulation protrusion ring disposed on the insulation substrate and in the sealed space, and the electrochemical cell is disposed at an inner side of the insulation protrusion ring.

6. The energy storage device of claim 5, wherein the insulation substrate and the insulation protrusion ring are formed in one piece.

7. The energy storage device of claim 6, wherein the insulation substrate and the insulation protrusion ring are made of low-temperature co-fired ceramics, high-temperature co-fired ceramics, or synthetic resin.

8. The energy storage device of claim 5, wherein the insulation protrusion ring is a laminated structure of dry films.

9. The energy storage device of claim 5, wherein the sealing structure comprises a metal support ring and a welding metal portion, the metal support ring is fixedly disposed on the circuit board, the insulation protrusion ring contacts an inner sidewall of the metal support ring, the conductive cover is disposed on the metal support ring, and the welding metal portion seals the conductive cover and the metal support ring.

10. The energy storage device of claim 1, wherein the conductive cover is provided in a cup structure, the circumference is located at a cup rim of the cup structure, the conductive cover is connected by the cup rim to the circuit board through the sealing structure, and the conductive cover comprises an insulation coating layer on an inner sidewall of the cup structure close to the cup rim.

11. The energy storage device of claim 1, wherein the conductive cover is provided in a cup structure, the circumference is located at a cup rim of the cup structure, the conductive cover is connected by the cup rim to the circuit board through the sealing structure, the circuit board comprises an insulation protrusion ring disposed on the insulation substrate and in the sealed space, the electrochemical cell is disposed at an inner side of the insulation protrusion ring, and the insulation protrusion ring contacts an inner sidewall of the cup structure.

12. The energy storage device of claim 1, wherein the metal coating layer covers the conductive cover and the exposed portion of the sealing structure completely.

13. A method of manufacturing an energy storage device, the method comprising the following steps:

(a) preparing a circuit board, the circuit board comprising an insulation substrate and a first electrode circuit and a second electrode circuit formed on the insulation substrate;

(b) preparing a conductive cover having a circumference;

(c) disposing cell contents;

(d) implementing a sealing process to put and fix the conductive cover above the circuit board and to form a sealing structure between the circuit board and the circumference of the conductive cover such that the circuit board, the conductive cover, and the sealing structure together form a sealed space, and the cell contents form an electrochemical cell in the sealed space, wherein the electrochemical cell is electrically connected to the first electrode circuit and the second electrode circuit respectively; and

(e) forming a metal coating layer successively covering a portion of the conductive cover, an exposed portion of the sealing structure, and a portion of the circuit board.

14. The method of claim 13, wherein in the step (a), the circuit board comprises an insulation protrusion ring disposed on the insulation substrate, in the step (c), the cell contents are disposed at an inner side of the insulation protrusion ring, and in the step (d), the insulation protrusion ring is disposed in the sealed space.

15. The method of claim 14, wherein the step (a) comprises implementing a dry film process to form a laminated structure of dry films on the insulation substrate as the insulation protrusion ring.

16. The method of claim 14, wherein the step (a) comprises forming the insulation substrate and the insulation protrusion ring by a one-piece production way.

17. The method of claim 13, wherein in the step (a), the circuit board comprises an insulation protrusion ring disposed on the insulation substrate, in the step (b), the conductive cover is provided in a cup structure, in the step (c), the cell contents are disposed at an inner side of the insulation protrusion ring, and the step (d) is implemented by the following steps:

forming an adherence layer at an outer side of the insulation protrusion ring on the circuit board;

putting the conductive cover above the circuit board such that the circumference of the conductive cover adheres onto the adherence layer; and

curing the adherence layer to form the sealing structure between the circuit board and the circumference of the conductive cover.

18. The method of claim 17, wherein in the step (d), the sealing structure is provided in a ring structure and comprises a welding metal portion formed by heating the adherence layer to a welding temperature, and the welding temperature is lower than a reflow temperature for the energy storage device.

19. The method of claim 17, wherein in the step (d), the sealing structure is provided in a ring structure and comprises a welding metal portion and an adhesive portion, the welding metal portion and the adhesive portion respectively are disposed in circle, and the adhesive portion is at an inner side of the welding metal portion.

20. The method of claim 13, wherein in the step (a), the circuit board comprises an insulation protrusion ring disposed on the insulation substrate, in the step (c), the cell contents are disposed at an inner side of the insulation protrusion ring, and the step (d) is implemented by the following steps:

forming a metal support ring on the circuit board such that the insulation protrusion ring contacts an inner sidewall of the metal support ring;

forming a metal solder layer on the metal support ring;

putting the conductive cover on the metal support ring such that the metal solder layer is disposed between the circumference and the metal support ring, and the cell contents form the electrochemical cell; and

heating the metal solder layer to form a welding metal portion for fixedly connecting the conductive cover and the metal support ring, wherein the metal support ring and the welding metal portion form the sealing structure.