Heterogeneous electrochemical supercapacitor and method of manufacture
First Claim
1. A double electric layer heterogeneous electrochemical capacitor, comprising:
- a sealable case for housing the components of said capacitor;
at least one positive electrode comprised of a porous, conductive lead-based material containing a dopant;
at least one negative electrode having a porous active mass portion affixed to a current collector portion;
a porous separator separating said at least one positive and negative electrode; and
an aqueous sulfuric acid electrolyte which penetrates into pores in each of said electrodes and said separator;
wherein approximately 60% to approximately 90% of a developed surface area of said active mass of said at least one negative electrode contains pores of between about 5 Å and
about 50 Å
in diameter; and
wherein said current collector portion of said negative electrode is made of a lead-tin alloy.
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Abstract
The present invention relates to a double electric layer heterogeneous electrochemical supercapacitor (HES) and a method of manufacture. Single-cell or multi-cell versions of the HES can be produced. Output characteristics of the HES are optimized by carefully controlling particular parameters of the HES'"'"' design and construction. For example, the ratio between the charging capacities of the positive electrode and negative electrode of the HES is carefully selected and controlled, an active material of higher efficiency than the active material used by typical electrochemical capacitors is preferably utilized in the construction of both the positive and negative electrodes, a separator with improved operating parameters is used, and the negative electrode current collector is preferably manufactured from a material having a matching layer—which ensures high conductivity, high hydrogen gassing overpotential, and high stability within a range of negative electrode operating potentials within the electrolyte environment of the HES.
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Citations
40 Claims
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1. A double electric layer heterogeneous electrochemical capacitor, comprising:
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a sealable case for housing the components of said capacitor; at least one positive electrode comprised of a porous, conductive lead-based material containing a dopant; at least one negative electrode having a porous active mass portion affixed to a current collector portion; a porous separator separating said at least one positive and negative electrode; and an aqueous sulfuric acid electrolyte which penetrates into pores in each of said electrodes and said separator; wherein approximately 60% to approximately 90% of a developed surface area of said active mass of said at least one negative electrode contains pores of between about 5 Å and
about 50 Å
in diameter; andwherein said current collector portion of said negative electrode is made of a lead-tin alloy. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A method of constructing a double electric layer heterogeneous electrochemical capacitor, comprising:
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providing a sealable case for housing the components of said capacitor; locating at least one positive electrode comprised of a porous, conductive lead-based material containing a dopant within said case; locating at least one negative electrode having a porous active mass portion affixed to a current collector portion within said case; placing a porous separator between said at least one positive and negative electrode; substantially filling said case with an aqueous sulfuric acid electrolyte which penetrates into pores in each of said electrodes and said separator; subjecting said at least one positive electrode to a forming process; and sealing said case; wherein approximately 60% to approximately 90% of a developed surface area of said active mass of said at least one negative electrode contains pores of between about 5 Å and
about 50 Å
in diameter; andwherein said current collector portion of said negative electrode is made of a lead-tin alloy. - View Dependent Claims (29, 30, 31, 32, 33, 34, 35, 36, 37, 38)
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39. A double electric layer heterogeneous electrochemical capacitor, comprising:
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a sealable case for housing the components of said capacitor; at least one positive electrode comprised of a mixture of Pb, Pb3O4 and PbO powders, said mixture doped with a combination of Ti7O13 and Ti8O15; at least one negative electrode having a porous active mass of an activated carbon material, said active mass affixed to a current collector comprised of a lead-tin alloy and coated with a conductive polymer matching layer; a porous separator separating said at least one positive and negative electrode; and an aqueous sulfuric acid electrolyte which penetrates into pores in each of said electrodes and said separator; wherein said active mass of said at least one negative electrode has a specific surface area of between about 1,200 m2/g and about 1,700 m2/g; and wherein approximately 60% to approximately 90% of a developed surface area of said active mass of said at least one negative electrode contains pores of between about 5 Å and
about 50 Å
in diameter.
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40. A method of constructing a multi-cell double electric layer heterogeneous electrochemical capacitor, comprising:
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providing a sealable case for housing the components of said capacitor; forming a plurality of positive electrodes from an active material mixture of Pb, Pb3O4 and PbO powders doped with a combination of Ti7O13 and Ti8O15; locating said plurality of positive electrodes within said case; forming a plurality of negative electrodes by affixing a porous active mass of an activated carbon material to a current collector that is comprised of a lead-tin alloy and is coated with a conductive polymer matching layer, approximately 60% to approximately 90% of a developed surface area of said active mass containing pores of between about 5 Å and
about 50 Å
in diameter;locating said plurality of negative electrodes within said case; placing a porous separator between each positive and negative electrode within said case; connecting current collector portions of each electrode to a corresponding terminal on said case; substantially filling said case with an aqueous sulfuric acid electrolyte which penetrates into pores in each of said electrodes and said separator; subjecting said plurality of positive electrodes to a forming process, whereby substantially all of said active material thereof is formed into β
-phase acicular crystals of between about 10.0 μ
m and about 12.0 μ
m in length; andsealing said case; wherein said positive and negative electrodes are located within said case in an alternating arrangement, such that there is one more negative electrode than positive electrode present.
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Specification