Supercapacitor structure

• US 6,181,545 B1
• Filed: 09/24/1998
• Issued: 01/30/2001
• Est. Priority Date: 09/24/1998
• Status: Expired due to Fees

• Current Assignee: Hey David A, Rutgers University
• Original Assignee: Telcordia Technologies Incorporated (Telefonaktiebolaget LM Ericsson)
• Inventors: Amatucci, Glenn G., Tarascon, Jean-Marie, DuPasquier, Aurelien
• Primary Examiner(s): Kincaid, Kristine
• Assistant Examiner(s): Thomas, Eric W.
• Application Number:
  US09/159,557
• Time in Patent Office: 859 Days
• Field of Search: 361/502, 361/508, 361/516, 361/512, 361/528, 361/500, 361/503, 361/504, 361/509, 361/522, 361/523, 361/524, 361/541, 429/192, 429/208, 429/170
• US Class Current: 361/502
• 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 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01G 11/70 characterised by their structure
• CPC Class Codes: H01G 11/72 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 4/30 Stacked capacitors H01G4/33 takes precedence
• CPC Class Codes: H01M 10/4264 with capacitors
• CPC Class Codes: H01M 16/00 Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 6/181 with polymeric electrolytes
• 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

Abstract

Supercapacitor cell electrode and separator elements formulated as membranes of plasticized polymeric matrix compositions are laminated with electrically conductive current collector elements to form flexible, unitary supercapacitor structures. The matrix plasticizer component is extracted from the laminate with polymer-inert solvent and replaced with electrolyte solution to activate the supercapacitor. Various arrangements of cell structure elements provide parallel and series cell structures which yield improved specific energy capacity and increased voltage output for utilization demands. The supercapacitor elements may also be laminated with similar polymeric rechargeable battery cell structures to provide hybrid devices capable of delivering both high energy and high power as needed in electronic systems.

Claims

1. A supercapacitor structure formed as a unitary flexible laminate structure comprising:

a) a first electrode member of first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element;

b) a first separator member, comprising a flexible, polymeric matrix membrane, said first separator member bonded to said first electrode member;

c) a second electrode member of second polarity opposite said first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element, said second electrode member bonded to said first separator member opposite said first electrode member;

d) a second separator member, comprising a flexible, polymeric matrix membrane, said second separator member bonded to said second electrode member opposite said first separator member; and

e) a third electrode member of said first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element, said third electrode member bonded to said second separator member opposite said second electrode member.

2. A supercapacitor structure comprising in contiguity a positive electrode member, a negative electrode member, and a separator member disposed therebetween, wherein

a) said positive electrode member comprises a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element bonded to said membrane,

b) said negative electrode member comprises a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element bonded to said membrane,

c) said separator member comprises a flexible, polymeric matrix membrane, and

d) said positive electrode member and said negative electrode member are bonded to opposite interface surfaces of said separator member to form a unitary flexible laminate structure.

3. A supercapacitor structure formed as a unitary flexible laminate structure comprising:

a) a first electrode member of first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element;

b) a first separator member, comprising a flexible, polymeric matrix membrane, said first separator member bonded to said first electrode member;

c) a bipolar electrode member, comprising a first electrode layer of second polarity opposite said first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein, a bimetallic collector element having a first metal layer appropriate for said first polarity and a second metal layer appropriate for said second polarity, said second metal layer of said bimetallic collector element bonded to said first electrode layer, and

a second electrode layer of said first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein, said second electrode layer bonded to said first metal layer of said bimetallic collector element, said bipolar electrode member bonded to said first separator member opposite said first electrode member such that said first electrode layer is in contact with said first separator member;

d) a second separator member, comprising a flexible, polymeric matrix membrane, said second separator member bonded to said bipolar electrode member opposite said first separator member such that said second electrode layer is in contact with said second separator member;

e) a third electrode member of said second polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element bonded to said membrane, said third electrode member bonded to said second separator member opposite said bipolar electrode member.

4. A hybrid supercapacitor and battery structure formed as a unitary flexible laminate structure comprising:

a) a supercapacitor electrode member of first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein and an electrically conductive current collector element;

b) a supercapacitor separator member, comprising a flexible, polymeric matrix membrane, said supercapacitor separator member being bonded to said supercapacitor electrode member;

c) a supercapacitor electrode layer of second polarity opposite said first polarity, comprising a flexible polymeric matrix membrane having an activated carbon powder uniformly distributed therein, said supercapacitor electrode layer being bonded to said supercapacitor separator member;

d) a common, electrically conductive current collector element of second polarity opposite said first polarity, said common collector element being bonded to said supercapacitor electrode layer;

e) a battery electrode layer of said second polarity, said battery electrode layer being bonded to said common collector element opposite said supercapacitor electrode layer;

f) a battery separator member bonded to said battery electrode layer opposite said common collector element; and

g) a battery electrode member of said first polarity having an electrically conductive current collector element, said battery electrode member being bonded to said battery separator member.

5. A hybrid supercapacitor and battery structure according to claim 4, wherein said battery electrode member comprises a plasticized polymeric matrix composition of a lithium intercalation compound, and said battery electrode layer comprises a plasticized polymeric composition of a material capable of intercalating lithium ions.