VERY THIN DIELECTRICS FOR HIGH PERMITTIVITY AND VERY LOW LEAKAGE CAPACITORS AND ENERGY STORING DEVICES

• US 20150000090A1
• Filed: 09/19/2014
• Published: 01/01/2015
• Est. Priority Date: 10/03/2008
• Status: Active Grant

• Current Assignee: Carver Scientific Inc.
• Original Assignee: Carver Scientific Inc.
• Inventors: Carver, David R., Carver, Robert G.
• Granted Patent: US 9,214,280 B2
• Time in Patent Office: Days
• US Class Current: 29/25.42
• CPC Class Codes: H01G 13/00 Apparatus specially adapted for manufacturing capacitors; Processes specially adapted for manufacturing capacitors not provided for in groups H01G4/00 - H01G11/00
• CPC Class Codes: H01G 4/06 Solid dielectrics
• CPC Class Codes: H01G 4/14 Organic dielectrics
• CPC Class Codes: H01G 4/20 using combinations of dielectrics from more than one of groups H01G4/02 - H01G4/06 H01G4/12 takes precedence
• CPC Class Codes: H01G 4/206 inorganic and synthetic material
• CPC Class Codes: Y10T 29/435 Solid dielectric type

Abstract

Methods are disclosed for creating extremely high permittivity dielectric materials for use in capacitors and energy storage devices. High permittivity materials suspended in an organic non-conductive media matrix with enhanced properties and methods for making the same are disclosed. Organic polymers, shellac, silicone oil, and/or zein formulations are utilized to produce thin film low conductivity dielectric coatings. Transition metal salts as salt or oxide matrices are formed at low temperatures utilizing mild reducing agents.

Claims

1. A method for the creation of an energy storage device that is comprised of a layered dielectric on a substrate, said method comprising:

creating a first dielectric film, said first dielectric film comprising a film material from the group consisting of a first insulative film material and a first film material that exhibits a high permittivity;

creating a second dielectric film in contact with the first dielectric film, said second dielectric film comprising a film material from the group consisting of a second insulative film material and a second film material that exhibits a high permittivity, said first dielectric film and said second dielectric film comprising dielectric film layers;

arranging the dielectric film layers between an electrically conductive first electrode and an electrically conductive second electrode, said electrically conductive first first electrode being in contact with the dielectric film layers and said electrically conductive first second electrode being opposite the first electrode and in contact with the dielectric film layers;

enhancing permittivity of the dielectric film layers by performing a permittivity enhancing treatment on at least a portion of the dielectric film layers, said permittivity enhancing treatment comprising a treatment from the group consisting of;

immersion of a portion of the dielectric film layers to be treated with the permittivity enhancing treatment in an electric field,

immersion of the portion of the dielectric film layers to be treated with the permittivity enhancing treatment in a magnetic field, and

introducing a reductant into the portion of the dielectric film layers to be treated with the permittivity enhancing treatment.

2. A method for the creation of an energy storage device according to claim 1, said permittivity enhancing treatment being performed on each of the first and second dielectric films during creation of the first and second dielectric layers.

3. A method for the creation of an energy storage device according to claim 1, said permittivity enhancing treatment being performed on each of the first and second dielectric films after arranging the dielectric film layers.

4. A method for the creation of an energy storage device that is comprised of a mixed dielectric on a substrate, said method comprising:

creating a dielectric film, said dielectric film comprising a film material from the group consisting of a first insulative film material and a first film material that exhibits a high permittivity;

enhancing permittivity of the dielectric film by performing a permittivity enhancing treatment on at least a portion of the dielectric film, said permittivity enhancing treatment comprising a treatment from the group consisting of;

immersion of a portion of the dielectric film to be treated with the permittivity enhancing treatment in an electric field,

immersion of the portion of the dielectric film to be treated with the permittivity enhancing treatment in a magnetic field, and

introducing a reductant into the portion of the dielectric film to be treated with the permittivity enhancing treatment; and

arranging the dielectric film between an electrically conductive first electrode and an electrically conductive second electrode, said electrically conductive first first electrode being in contact with the dielectric film and said electrically conductive first second electrode being opposite the first electrode and in contact with the dielectric film.

5. A method for the creation of an energy storage device according to claim 4, said permittivity enhancing treatment being performed on the dielectric film during creation of the dielectric film.

6. A method for the creation of an energy storage device according to claim 4, said permittivity enhancing treatment being performed on the dielectric film after arranging the dielectric film.

7. A method for creating a spreadable thin coating of high permittivity dielectric material on a substrate, said method comprising:

creating a wetting agent solution by combining an organic polymer with a solvent and mixing the combined organic polymer with the solvent;

after mixing the combined organic polymer with the solvent, optionally removing any particulate matter not dissolved in the wetting agent solution;

combining said wetting agent solution with a high permittivity dielectric material;

mixing said wetting agent solution with the high permittivity dielectric material to create a smooth slurry; and

spreading said smooth slurry in a thin and even coating onto a first substrate.

8. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 7, further comprising

adding a drying agent to said wetting agent solution, and

allowing the wetting agent to dry.

9. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 7, said organic polymer comprising a substance from the group consisting of parylene, shellac, zein and silicon oil.

10. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 7, further comprising placement of a second substrate onto said smooth slurry opposite said first substrate, said smooth slurry being disposed between said first substrate and said second substrate, and

applying an electric field by connection of a voltage source across said first substrate and said second substrate.

11. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 10, wherein the strength of said electric field is greater than 100 V/cm.

12. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 11, further comprising, while applying the electric field, setting the smooth slurry by performing a step from the group consisting of curing the smooth slurry and drying the smooth slurry.

13. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 7, further comprising placement of a second substrate onto said smooth slurry opposite said first substrate, said smooth slurry being disposed between said first substrate and said second substrate, said smooth slurry, first substrate and second substrate thereby forming an assembly, and said first substrate having a first outer surface and said second substrate having a second outer surface;

and

placing said assembly between magnetic north and south poles of a magnetic source such that a magnetic field between the north pole of said magnetic source and the south pole of said magnetic source is about perpendicular to the first outer surface and the second outer surface.

14. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 13, wherein the strength of said magnetic field is greater than 1 Gauss.

15. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 14, further comprising, while said assembly is placed between magnetic north and south poles of the magnetic source, setting the smooth slurry by performing a step from the group consisting of curing the smooth slurry and drying the smooth slurry.

16. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 10, said smooth slurry, first substrate and second substrate forming an assembly, and said first substrate having a first outer surface and said second substrate having a second outer surface;

and further comprising

placing said assembly between magnetic north and south poles of a magnetic source such that a magnetic field between the north pole of said magnetic source and the south pole of said magnetic source is about perpendicular to the first outer surface and the second outer surface, while applying said electric field.

17. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 16, wherein the strength of said magnetic field is greater than 1 Gauss.

18. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 17, further comprising, while said assembly is placed between magnetic north and south poles of the magnetic source and said electric field is applied, setting the smooth slurry by performing a step from the group consisting of curing the smooth slurry and drying the smooth slurry.

19. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 7, further comprising adding a reducing agent to said wetting agent solution.

20. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 19, said reducing agent comprising sodium borohydride.

21. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 7, further comprising adding an iron cation to said wetting agent solution.

22. A method for creating a spreadable thin coating of high permittivity dielectric material on a substrate, said method comprising:

creating a first solution comprising a polymer mixed with a cross-linking agent;

combining said first solution with a high permittivity dielectric material;

mixing said first solution with the high permittivity dielectric material to create a smooth slurry; and

spreading said smooth slurry in a thin and even coating onto a first substrate.

23. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 22, polymer comprising a substance from the group consisting of a parylene, shellac, zein and silicon;

and said cross linking agent comprising an agent from the group consisting of divinylsilane, cyanoacrylate, and an epoxy.

24. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 22, further comprising adding an iron cation to the polymer.

25. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 22, further comprising adding a reducing agent to said first solution.

26. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate of claim 22, said reducing agent comprising sodium borohydride.

27. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate according to claim 22, said method further comprising removing particulate matter not dissolved into said first solution.

28. The method for creating a spreadable thin coating of high permittivity dielectric material on a substrate according to claim 22, further comprising applying a second substrate onto said smooth slurry opposite said first substrate, and

applying a permittivity enhancing field across across said first substrate, said slurry and said second substrate, said permittivity enhancing field comprising a field from the group consisting of

an electric field generated by connection of a voltage source across said first substrate and said second substrate, and

a magnetic field provided by placing said said first substrate, said slurry and said second substrate between magnetic north and south poles of a magnetic source.