Charge storage device

• US 7,009,833 B2
• Filed: 02/07/2005
• Issued: 03/07/2006
• Est. Priority Date: 12/05/1998
• Status: Expired due to Term

• Current Assignee: Cap-Xx Ltd.
• Original Assignee: Energy Storage Systems, Inc. (ESS Tech, Inc.)
• Inventors: Jones, Philip Andrew, Pynenburg, Rory Albert James, Vassallo, Anthony Michael, Keshishian, Sarkis, Paul, George Lange, Pandolfo, Anthony Gaetano, Mahon, Peter John
• Primary Examiner(s): Reichard, Dean A.
• Assistant Examiner(s): Ha, Nguyen T.
• Application Number:
  US11/050,762
• Publication Number:
  US 20050135046A1
• Time in Patent Office: 393 Days
• Field of Search: 361502-504, 361508-509, 361/512, 361/516, 361/519, 361/520, 361/523, 361/525, 361/528, 361/529, 361/530, 429/30, 429/44, 429306-309
• US Class Current: 361/502
• CPC Class Codes: H01G 11/12 Stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/22 Electrodes
• CPC Class Codes: H01G 11/24 characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01G 11/42 Powders or particles, e.g. composition thereof
• CPC Class Codes: H01G 11/52 Separators
• CPC Class Codes: H01G 11/72 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/74 Terminals, e.g. extensions of current collectors
• CPC Class Codes: H01G 11/76 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 9/008 Terminals
• CPC Class Codes: H01G 9/045 based on aluminium
• CPC Class Codes: H01G 9/048 characterised by their structure H01G11/22 takes precedence
• CPC Class Codes: H01G 9/08 Housing; Encapsulation
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A charge storage device comprising: a first electrode, a second electrode being opposed to and spaced apart from the first electrode; a porous separator disposed between the electrodes; a sealed package for containing the electrodes, the separator and an electrolyte in which the electrodes are immersed; and a first terminal and a second terminal being electrically connected to the first electrode and the second electrode respectively and both extending from the package to allow external electrical connection to the respective electrodes, wherein the gravimetric FOM of the device is greater than about 2.1 Watts/gram. Also described is a method of manufacturing a charge storage device, the method comprising the steps of: providing a first electrode; disposing a second electrode in opposition to and spaced apart from the first electrode; disposing a porous separator between the electrodes; containing within a sealed package the electrodes, the separator and an electrolyte, wherein the electrodes are immersed in the electrolyte; and electrically connecting a first terminal and a second terminal to the first electrode and the second electrode respectively such that the terminals extending from the package to allow external electrical connection to the respective electrodes, wherein the gravimetric FOM of the device is greater than about 2.1 Watts/gram.

Claims

1. A charge storage device comprising:

a charge storage cell including;

(a) a first electrode;

(b) a second electrode being opposed to and spaced apart from the first electrode; and

(c) a porous separator disposed between the electrodes;

a sealed package for containing the cell and an electrolyte in which the cell is immersed; and

at least two terminals extending from the package to allow external electrical connection to the cell, wherein the volumetric FOM (Figure of Merit) of the device is greater than about 3.2 Watts/cm³ and the device has a maximum thickness of less than about 7 mm.

2. A device according to claim 1 wherein the maximum thickness is less than about 5 mm.

3. A device according to claim 1 wherein the maximum thickness is less than about 0.4 mm.

4. A device according to claim 1 wherein the volumetric FOM is in the range of about 3.2 Watts/cm³ to 4 Watts/cm³.

5. A device according to claim 1 wherein the volumetric FOM is in the range of about 4 Watts/cm³ to 5 Watts/cm³.

6. A device according to claim 1 wherein the volumetric FOM is in the range of about 5 Watts/cm³ to 7 Watts/cm³.

7. A device according to claim 1 wherein the volumetric FOM is in the range of about 7 Watts/cm³ to 8 Watts/cm³.

8. A device according to claim 1 wherein the volumetric FOM is greater than about 8 Watts/cm³.

9. A device according to claim 1 including a plurality of cells.

10. A device according to claim 9 wherein the package contains the cells.

11. A device according to claim 9 wherein the cells are connected in series and/or parallel with each other.

12. A device according to claim 1 wherein at least one of the electrodes includes a layer containing a carbon.

13. A device according to claim 1 wherein the first electrode, the second electrode and the separator are wound together in a spiral.

14. A device according to claim 1 wherein the first electrode and the second electrode are folded together.

15. A device according to claim 14 wherein the electrodes are rectangular and are centrally folded about an axis to form a capacitive element.

16. A device according to claim 15 wherein a plurality of the capacitive elements are stacked and electrically connected in parallel to provide a predetermined electrical characteristic.

17. A device according to claim 1 including a plurality of individually packaged cells, all the cells being electrically connected.

18. A device according to claim 17 wherein the cells are electrically connected in series.

19. A device according to claim 17 wherein the cells are electrically connected in parallel.

20. A charge storage device including:

a charge storage cell including;

(a) a first electrode having a first layer including a carbon having a surface area greater than 400 m²/gram;

(b) a second electrode having a second layer including a carbon having a surface area greater than 400 m²/gram; and

(c) a porous separator disposed between the electrodes;

a sealed package for containing the cell and an organic electrolyte in which the cell is immersed, wherein the first and second layers are opposed and spaced apart; and

at least two terminals that extend from the package to allow external electrical connection to the cell, wherein the volumetric FOM (Figure of Merit) of the device is greater than about 1.1 Watts/cm³ and the device has a maximum thickness of less than about 7 mm.

21. A device according to claim 20 wherein the maximum thickness is less than about 5 mm.

22. A device according to claim 20 wherein the maximum thickness is less than about 0.4 mm.

23. A device according to claim 20 wherein the surface area of the carbon is at least 1200 m²/gram.

24. A device according to claim 20 wherein at least one of the layers contains more than one type of carbon.

25. A device according to claim 20 including a plurality of cells.

26. A device according to claim 25 wherein the package contains the cells.

27. A device according to claim 25 wherein the cells are connected in series and/or parallel with each other.

28. A device according to claim 20 wherein at least one of the carbon layers includes particulate carbon.

29. A device according to claim 20 wherein both the layers include particulate carbon.

30. A charge storage device including:

a charge storage cell including;

(a) a first electrode;

(b) a second electrode being opposed to and spaced apart from the first electrode; and

(c) a porous separator disposed between the electrodes;

a sealed package for containing the cell and an electrolyte in which the cell is immersed; and

at least two terminals that extend from the package to allow external electrical connection to the cell, wherein the gravimetric power maximum of the device is greater than about 12.5 Watts/gram and the device has a maximum thickness of less than about 7 mm.

31. A device according to claim 30 wherein the maximum thickness is less than about 5 mm.

32. A device according to claim 30 wherein the maximum thickness is less than about 0.4 mm.

33. A device according to claim 30 wherein gravimetric power maximum is greater than about 15 Watts/gram.

34. A device according to claim 33 wherein gravimetric power maximum is greater than about 17 Watts/gram.

35. A device according to claim 34 wherein gravimetric power maximum is greater than about 26 Watts/gram.

36. A device according to claim 30 including a plurality of cells.

37. A device according to claim 36 wherein the package contains the cells.

38. A device according to claim 36 wherein the cells are connected in series and/or parallel with each other.

39. A device according to claim 36 wherein at least one of the electrodes includes a layer containing a carbon.

40. A device according to claim 39 wherein the layer contains a particulate carbon.

41. A charge storage device including:

a charge storage cell having;

(a) a first electrode;

(b) a second electrode being opposed to and spaced apart from the first electrode; and

(c) a porous separator disposed between the electrodes;

a sealed package for containing the cell and an electrolyte in which the cell is immersed; and

at least two terminals that extend from the package to allow external electrical connection to the cell, wherein the volumetric power maximum of the device is greater than about 35 Watts/cm³ and the device has a maximum thickness of less than about 7 mm.

42. A device according to claim 41 wherein the maximum thickness is less than about 5mm.

43. A device according to claim 41 wherein the maximum thickness is less than about 0.4 mm.

44. A device according to claim 41 including a plurality of cells.

45. A device according to claim 41 wherein the package contains the cells.

46. A device according to claim 44 wherein the cells are connected in series and/or parallel with each other.

47. A device according to claim 41 wherein at least one of the electrodes includes a layer containing a carbon.

48. A device according to claim 47 wherein the layer contains a particulate carbon.

49. A charge storage device including:

a charge storage cell including;

(a) a first electrode having a first layer including a carbon having a surface area of at least about 400 m²/gram;

(b) a second electrode having a second layer including a carbon having a surface area of at least about 400 m²/gram, the second layer being opposed to and spaced apart from the first layer;

(c) a porous separator disposed between the electrodes;

a sealed package for containing the cell and an electrolyte in which the cell is immersed; and

at least two terminals that extend from the package to allow external electrical connection to the respective electrodes, wherein the gravimetric power maximum of the device is greater than about 4.8 Watts/gram and the device has a maximum thickness of less than about 7 mm.

50. A device according to claim 49 wherein the maximum thickness is less than about 5 mm.

51. A device according to claim 49 wherein the maximum thickness is less than about 0.4 mm.

52. A device according to claim 49 including a plurality of cells.

53. A device according to claim 52 wherein the package contains the cells.

54. A device according to claim 52 wherein the cells are connected in series and/or parallel with each other.

55. A device according to claim 49 wherein the surface area of the carbon is at least 1200 m²/gram.

56. A device according to claim 49 wherein at least one of the layers contains more than one type of carbon.

57. A device according to claim 49 wherein at least one of the layers contains a particulate carbon.

58. A charge storage device comprising:

a charge storage cell including;

(a) a first electrode;

(b) a second electrode being opposed to and spaced apart from the first electrode; and

(c) a porous separator disposed between the electrodes;

a sealed package for containing the cell and an electrolyte in which the cell is immersed; and

at least two terminals that extend from the package to allow external electrical connection to the respective electrodes, wherein the gravimetric FOM (Figure of Merit) of the device is greater than about 2.1 Watts/gram and the device has a maximum thickness of less than about 7 mm.

59. A device according to claim 58 wherein the maximum thickness is less than about 5 mm.

60. A device according to claim 58 wherein the maximum thickness is less than about 0.4 mm.

61. A device according to claim 58 wherein the gravimetric FOM of the device is greater than about 2.5 Watts/gram.

62. A device according to claim 61 wherein the gravimetric FOM of the device is greater than about 3 Watts/gram.

63. A device according to claim 62 wherein the gravimetric FOM of the device is greater than about 3.5 Watts/gram.

64. A device according to claim 63 wherein the gravimetric FOM of the device is greater than about 5 Watts/gram.

65. A device according to claim 58 including a plurality of cells.

66. A device according to claim 65 wherein the package contains the cells.

67. A device according to claim 65 wherein the cells are connected in series and/or parallel with each other.

68. A device according to claim 58 wherein at least one of the electrodes includes a layer containing a carbon.

69. A device according to claim 68 wherein the layer contains a particulate carbon.