Electrical-energy-storage unit (EESU) utilizing ceramic and integrated-circuit technologies for replacement of electrochemical batteries
First Claim
1. A method for making an electrical-energy-storage unit comprising components fabricated by the method steps as follow;
- a) preparing a wet-chemical-prepared calcined composition-modified barium titanate powder derived from a solution of precursors;
Ba(NO3)2, Ca(NO3)2.4H2O, Nd(NO3)3.6H2O, Y(NO3)3.4H2O, Mn(CH3COO)2.4H2O, ZrO(N3O)2, and [CH3CH(O—
)COONH4]2Ti(OH)2 in deionize water heated to 80°
C., and a separate solution of (CH3)4NOH made in deionized water and heated to 80°
-85°
C., then mixing the solutions by pumping the heated ingredient streams simultaneously through a coaxial fluid mixer producing coprecipitated powder, then collecting the coprecipitated powder in a drown-out vessel and refluxing at a temperature of 90°
-95°
C. for 12 hours, then filtering, washing with deionized-water, drying, and then calcining 1050°
C. in air;
b) fabricating an aluminum oxide (Al2O3) coating of 100 Å
thickness onto the wet-chemical-prepared calcined composition-modified barium titanate powder, with the use of aluminum nitrate nonahydrate precursor applied by wet chemical means, then calcining at 1050°
C., resulting in a single-coated calcined composition-modified barium titanate powder;
c) fabricating onto the alumina-coated composition-modified barium titanate powder, a second uniform coating of 100 Å
of calcium magnesium aluminosilicate glass derived from alcohol-soluble precursors;
calcium methoxide or calcium isopropoxide, magnesium methoxide or magnesium ethoxide, aluminum ethoxide or aluminum isopropoxide or aluminum isopropoxide, and tetraethyl orthosilicate are applied by wet chemical means which upon calcining at 500°
C. results in a double-coated composition-modified barium titanate powder;
d) blending, this double-coated composition-modified barium titanate powder with a screen-printing ink containing appropriate plastic resins surfactants, lubricants, and solvents to provide a suitable rheology for screen printing;
e) screen-printing into interleaved multilayers of alternating offset nickel electrode layers 12 and double-coated calcined composition-modified barium titanate high-relative-permittivity layers 11 with the use of screening inks having the proper rheology for each of the layers;
f) drying and cutting the screen-punted multilayer components 15 into a specified rectangular area;
g) sintering the screen-printed multilayer components 15, first at a temperature of 350°
C. for a specified length of time, then at 850°
C. for a specified length of time, to form closed-pore porous ceramic bodies; and
h) hot isostatically pressing the closed-pore porous ceramic bodies, at a temperature of 700°
C. with a specified pressure, into a void-free condition;
i) grinding and each side of the component to expose the alternating offset interleaved nickel electrodes 12;
j) connecting nickel side bars 14 to each side of the components 15, that have the interleaved and alternating offset nickel electrodes 12 exposed, by applying nickel ink with the proper rheology to each side and clamping the combinations together;
k) heating the components and side nickel bar combination 14-15 800°
C., and time duration of 20 minutes to bond them together;
l) wave soldering each side of the conducting bars;
m) assembling the components 15 with the connected nickel side bars 14 into the first array, utilizing unique tooling and solder-bump technology;
n) assembling the first arrays into the second array;
o) assembling the second arrays into the EESU final assembly.
1 Assignment
0 Petitions
Accused Products
Abstract
An electrical-energy-storage unit (EESU) has as a basis material a high-permittivity composition-modified barium titanate ceramic powder. This powder is double coated with the first coating being aluminum oxide and the second coating calcium magnesium aluminosilicate glass. The components of the EESU are manufactured with the use of classical ceramic fabrication techniques which include screen printing alternating multilayers of nickel electrodes and high-permittivitiy composition-modified barium titanate powder, sintering to a closed-pore porous body, followed by hot-isostatic pressing to a void-free body. The components are configured into a multilayer array with the use of a solder-bump technique as the enabling technology so as to provide a parallel configuration of components that has the capability to store electrical energy in the range of 52 kW·h. The total weight of an EESU with this range of electrical energy storage is about 336 pounds.
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Citations
17 Claims
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1. A method for making an electrical-energy-storage unit comprising components fabricated by the method steps as follow;
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a) preparing a wet-chemical-prepared calcined composition-modified barium titanate powder derived from a solution of precursors;
Ba(NO3)2, Ca(NO3)2.4H2O, Nd(NO3)3.6H2O, Y(NO3)3.4H2O, Mn(CH3COO)2.4H2O, ZrO(N3O)2, and [CH3CH(O—
)COONH4]2Ti(OH)2 in deionize water heated to 80°
C., and a separate solution of (CH3)4NOH made in deionized water and heated to 80°
-85°
C., then mixing the solutions by pumping the heated ingredient streams simultaneously through a coaxial fluid mixer producing coprecipitated powder, then collecting the coprecipitated powder in a drown-out vessel and refluxing at a temperature of 90°
-95°
C. for 12 hours, then filtering, washing with deionized-water, drying, and then calcining 1050°
C. in air;
b) fabricating an aluminum oxide (Al2O3) coating of 100 Å
thickness onto the wet-chemical-prepared calcined composition-modified barium titanate powder, with the use of aluminum nitrate nonahydrate precursor applied by wet chemical means, then calcining at 1050°
C., resulting in a single-coated calcined composition-modified barium titanate powder;
c) fabricating onto the alumina-coated composition-modified barium titanate powder, a second uniform coating of 100 Å
of calcium magnesium aluminosilicate glass derived from alcohol-soluble precursors;
calcium methoxide or calcium isopropoxide, magnesium methoxide or magnesium ethoxide, aluminum ethoxide or aluminum isopropoxide or aluminum isopropoxide, and tetraethyl orthosilicate are applied by wet chemical means which upon calcining at 500°
C. results in a double-coated composition-modified barium titanate powder;
d) blending, this double-coated composition-modified barium titanate powder with a screen-printing ink containing appropriate plastic resins surfactants, lubricants, and solvents to provide a suitable rheology for screen printing;
e) screen-printing into interleaved multilayers of alternating offset nickel electrode layers 12 and double-coated calcined composition-modified barium titanate high-relative-permittivity layers 11 with the use of screening inks having the proper rheology for each of the layers;
f) drying and cutting the screen-punted multilayer components 15 into a specified rectangular area;
g) sintering the screen-printed multilayer components 15, first at a temperature of 350°
C. for a specified length of time, then at 850°
C. for a specified length of time, to form closed-pore porous ceramic bodies; and
h) hot isostatically pressing the closed-pore porous ceramic bodies, at a temperature of 700°
C. with a specified pressure, into a void-free condition;
i) grinding and each side of the component to expose the alternating offset interleaved nickel electrodes 12;
j) connecting nickel side bars 14 to each side of the components 15, that have the interleaved and alternating offset nickel electrodes 12 exposed, by applying nickel ink with the proper rheology to each side and clamping the combinations together;
k) heating the components and side nickel bar combination 14-15 800°
C., and time duration of 20 minutes to bond them together;
l) wave soldering each side of the conducting bars;
m) assembling the components 15 with the connected nickel side bars 14 into the first array, utilizing unique tooling and solder-bump technology;
n) assembling the first arrays into the second array;
o) assembling the second arrays into the EESU final assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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Specification