Low impedance electrochemical cell

• US 6,614,647 B2
• Filed: 05/06/2002
• Issued: 09/02/2003
• Est. Priority Date: 05/07/2001
• Status: Expired due to Term

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Kamath, Hundi P.
• Primary Examiner(s): Reichard, Dean A.
• Assistant Examiner(s): THOMAS, ERIC W
• Application Number:
  US10/140,006
• Publication Number:
  US 20020163772A1
• Time in Patent Office: 484 Days
• Field of Search: 361/502, 361/503, 361/508-520, 361/535-540
• US Class Current: 361/502
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/52 Separators
• 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: Y02E 60/13 Energy storage using capacitors

Abstract

Provided are electrochemical (e.g., double layer capacitor) cell designs and methods of their manufacture, which reduce cell impedance and increase volumetric capacitance while maintaining inter-electrode dielectric integrity and cell performance. The designs eliminate the contiguous separator material used as the dielectric between the electrodes in conventional double layer capacitor cells. The separator is replaced by a noncontiguous array of dielectric particles, such as glass beads or fibers, sized and distributed to provide substantially uniform separation between the electrodes. The remaining space between the electrodes unoccupied by the dielectric particles is filled with electrolyte. In this way, a much greater proportion of the dielectric space between the electrodes is available for ionic transport. Glass beads and fibers are available with diameters less than that available for currently-used separator materials. Thus, the distance between the electrodes may be reduced without compromising dielectric integrity. The result is a lower impedance, higher volumetric capacitance double layer capacitor cell.

Claims

1. An electrochemical cell, comprising:

a cell container;

a first electrode provided within the cell container;

a second electrode provided within the cell container;

a noncontiguous dielectric provided within the cell container and disposed between the electrodes; and

an electrolyte provided within the cell container.

2. The electrochemical cell of claim 1, wherein each of said first and second electrodes comprises carbon.

3. The electrochemical cell of claim 2, wherein each of said first and second electrodes further comprises a current collector attached to said carbon.

4. The electrochemical cell of claim 2, wherein said carbon is a carbon aerogel disk.

5. The electrochemical cell of claim 4, wherein said carbon aerogel disk is monolithic.

6. The electrochemical cell of claim 1, wherein said noncontiguous dielectric comprises an array of particles having a substantially uniform diameter.

7. The electrochemical cell of claim 6, wherein said particles are selected from the group consisting of glass beads and glass fibers.

8. The electrochemical cell of claim 7, wherein said particles are glass beads.

9. The electrochemical cell of claim 8, wherein beads have a diameter of about 1 to 10 microns.

10. The electrochemical cell of claim 8, wherein beads have a diameter of about 3 to 5 microns.

11. The electrochemical cell of claim 7, wherein the particles are glass fibers.

12. The electro chemical cell of claim 1, wherein the noncontiguous dielectric occupies between 10% and 80% of the volume between the electrodes.

13. The electrochemical cell of claim 1, wherein said cell container comprises polymer-laminated aluminum foil.

14. The electrochemical cell of claim 1, wherein said electrolyte comprises tetraethylammonium tetrafluoroborate (Et₄N(BF₄)) salt dissolved in an organic solvent.

15. The electrochemical cell of claim 1, wherein said cell is a double layer capacitor cell.

16. A double layer capacitor cell, comprising:

a cell container;

a first carbon aerogel electrode provided within the cell container;

a second carbon aerogel electrode provided within the cell container;

a noncontiguous dielectric comprising glass beads having a substantially uniform diameter of about 3 to 5 microns provided within the cell container and disposed between the electrodes; and

an electrolyte provided within the cell container.

17. An electrochemical structure, comprising:

a first carbon aerogel electrode;

a second carbon aerogel electrode; and

a noncontiguous dielectric disposed between the electrodes.

18. The structure of claim 17, wherein said noncontiguous dielectric comprises an array of particles having a substantially uniform diameter of about 1 to 10 microns.

19. The structure of claim 18, wherein said particles are glass beads having a diameter of about 4 to 5 microns.

20. The structure of claim 18, wherein the particles are glass fibers.