Electrical energy devices

• US 5,766,789 A
• Filed: 12/28/1995
• Issued: 06/16/1998
• Est. Priority Date: 09/29/1995
• Status: Expired due to Fees

• Current Assignee: Energetics Systems Corporation
• Original Assignee: Energetics Systems Corporation
• Inventors: James, David, Kelley, John J., Allison, Daniel B. II, Doe, James B.
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US08/581,298
• Time in Patent Office: 901 Days
• Field of Search: 429/44, 429/232, 429/235, 429/236, 204/431
• US Class Current: 429/517
• CPC Class Codes: H01G 4/08 Inorganic dielectrics
• CPC Class Codes: H01G 4/12 Ceramic dielectrics H01G4/085 takes precedence
• CPC Class Codes: H01M 4/664 Ceramic materials
• CPC Class Codes: H01M 4/8621 containing only metallic or ceramic material, e.g. made by sintering or sputtering
• CPC Class Codes: H01M 6/48 with bipolar electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

The performance of electrochemical energy devices such as batteries, fuel cells, capacitors and sensors is enhanced by the use of electrically conducting ceramic materials in the form of fibers, powder, chips and substrates.

Claims

1. An electrical energy device having at least one component having conductive ceramic fibers therein, said fibers having a length of about 10 to about 10,000μ

(1μ

=10^-6 m) and a length to diameter ratio of about 1 to about 20.

2. The device of claim 1 wherein said conductive ceramic fibers include a metal containing additive.

3. The device of claim 2 wherein said device is capable of at least one of generating electrical energy or storing electrical energy.

4. The device of claim 3 wherein said device is at least one of batteries, fuel cells, capacitors, and sensors.

5. The device of claim 4 wherein said device is a battery.

6. The device of claim 5 wherein said battery is at least one of lead-acid batteries, alkaline batteries, sulfur containing batteries, lithium containing batteries, and nickel containing batteries.

7. The device of claim 2 wherein said conductive ceramic fibers have at least one metal coating thereon.

8. The device of claim 7 wherein said metal coating is substantially the same composition as said metal containing additive in said fibers.

9. The device of claim 6 wherein said battery is a lead acid battery.

10. The device of claim 6 wherein said battery is an alkaline battery.

11. The device of claim 10 wherein said alkaline battery is any of Zn-AgO₂, Zn-AgO, Zn-AgNO₂, Zn-Ag₂ Pbo₂, Zn-HgO, Zn-MnO₂.

12. The device of claim 11 wherein said alkaline battery includes at least one conductive ceramic fiber selected from the group of titanium suboxides and titanium superoxides.

13. The device of claim 6 wherein said sulfur containing battery is a sodium-sulfur battery.

14. The device of claim 13 wherein said sodium-sulfur battery includes at least one conductive ceramic fiber comprising Tio and an oxide selected from the group of Ti₄ O₇, Ti₅ O₉, copper-intercalated Ti₄ O₇ and copper-intercalated Ti₅ O₉.

15. The device of claim 6 wherein said device is a lithium containing battery of any of Li-AgV₂ O₅, Li-CF, Li-CuO, Li-FeS, Li-FeS₂, Li-I, Li-MnO₂, Li-MOS₂, Li-V₂ O₅, Li-TiS₂, Li-SOCl₂, Li-SO₂.

16. The device of claim 15 wherein said lithium containing battery includes at least one conductive ceramic fiber selected from the group of substoichiometric titanium and superstoichiometric titanium dioxide.

17. The device of claim 6 wherein said device is a Ni containing battery of any one of Ni-Cd, Ni-H₂, Ni-Zn, Ni-MH and Ni-Fe.

18. The Ni containing battery of claim 17 wherein said battery includes at least one conductive ceramic fiber selected from the group of Ti₄ O₇ intercalated with Cu, and Ti₅ O₉ intercalated with Cu.

19. The device of claim 3 wherein said device is a fuel cell.

20. The device of claim 3 wherein said device includes at least one electrode having conductive ceramic fibers therein, said electrode having at least one of a current collector and active material.

21. The device of claim 20 wherein said conductive ceramic fibers are present in at least one of said current collector or said material.

22. The device of claim 19 wherein said fibers are present in said collector in an amount of about 50 to 100% by weight of said collector.

23. The device of claim 20 wherein said fibers are present in said paste in an amount of about to % by weight of said paste.

24. The device of claim 21 wherein said matrix material is selected from the group of oxides, carbides, nitrides, and borides.

25. The device of claim 24 wherein said oxide is selected from the group of substoichiometric titanium dioxides, superstoichiometric titanium dioxides, and perovskite oxides.

26. The device of claim 25 wherein said perovskite oxide is tungsten oxide.

27. The device of claim 24 wherein said metal containing additive is selected from the group of Cu, Ni, Co, Ag, Pt, Ta, Zn, Mg, Ru, Ir, Nb, V, Sn, SnO, SnO₂, Pb, Pd, Ir and alloys thereof.

28. The device of claim 27 wherein said oxide is substoichiometric titanium dioxides and said metal containing additive is selected from the group of Sn, SnO, and SnO2.

29. The device of claim 3 wherein said device is in the form of a capacitor.

30. The device of claim 29 wherein said capacitor includes conductive ceramic fiber therein.

31. The device of claim 30 wherein said conductive ceramic fibers are selected from the group of titanium suboxide and titanium superoxides.

32. The device of claim 3 wherein said sensors include at least one of thermal sensors and chemical sensors.

33. The device of claim 32 wherein said thermal sensor is in the form of single fibers or bundles of conductive, doped ceramic fibers.

34. The device of claim 33 wherein said chemical sensor is in the form of a sheet, paper, nonwoven or woven mat, and composed principally of conductive ceramic fibers.

40. The device of claim 5 wherein said battery comprises an anode compartment having a lithium material of thermodynamic activity less than that of lithium metal.

41. The device of claim 40 wherein said battery further comprises a cathode compartment that comprises a material containing manganese.

42. The device of claim 40 wherein said battery includes an electrolyte material that comprises an organic polymer.

43. The device of claim 40 wherein the lithium material is intercalated into a carbon material selected from the group of graphite and petroleum coke.

44. The device of claim 5 wherein the battery is of bipolar design.

35. A lead-acid battery having a plurality of electrodes therein, said electrode comprising an active material composition and a current collector, wherein conductive ceramic fibers are included in at least one said active material and said current collector.

36. The lead acid battery of claim 35 wherein said active material composition is lead dioxide and said conductive ceramic fibers have a substoichiometric titanium dioxide matrix and a Sn-Pb alloy dispersed throughout said matrix.

37. The lead acid battery of claim 36 wherein said current collector comprises conductive ceramic fibers from the group of substoichiometric titanium and superstoichiometric titanium.

38. The lead acid battery of claim 37 wherein said ceramic fiber comprises substoichiometric titanium dioxide having Sn-Pb alloy therein.

39. The lead acid battery of claim 38 wherein said substoichiometric titanium dioxide is Ti₄ O₇.

45. A battery which comprises an electrically conductive ceramic comprising electrically conductive vanadium oxides wherein said conductive vanadium oxide includes therein at least one of M oxides and free metal where M is selected from the group of Cr, Cu, Ni, Pt, Ta, Zn, Mg, Ru, Ir, Nb, V, or mixtures thereof, and said vanadium oxide has the formula VOx where x is between about 1 and 2.5.

46. A battery which comprises electrically conductive ceramic fibers comprising an oxide selected from the group of Ti₄ O₇ and Ti₅ O₉ coated with a metal.