Electrode array for use in electrochemical cells

• US 7,368,191 B2
• Filed: 07/23/2002
• Issued: 05/06/2008
• Est. Priority Date: 07/25/2001
• Status: Expired due to Fees

• Current Assignee: Biosource, Incorporated
• Original Assignee: Biosource, Incorporated
• Inventors: Zulkiewicz, Jon, Andelman, Marc D.
• Primary Examiner(s): SINES, BRIAN J
• Application Number:
  US10/484,981
• Publication Number:
  US 20050079409A1
• Time in Patent Office: 2,114 Days
• Field of Search: 429/12, 429/13, 429/40, 429/22, 429/50, 429/61
• US Class Current: 429/523
• CPC Class Codes: C02F 1/46109 Electrodes
• CPC Class Codes: C02F 1/4691 Capacitive deionisation
• CPC Class Codes: C02F 2001/46133 characterised by the material
• CPC Class Codes: C02F 2001/46152 characterised by the shape or form electrodes in particulate form or with conductive or non-conductive particles between them C02F1/46114
• CPC Class Codes: C02F 2201/46195 Cells containing solid electrolyte
• CPC Class Codes: H01G 11/14 Arrangements or processes for adjusting or protecting hybrid or EDL capacitors emergency protective circuit arrangements specially adapted for capacitors, and effecting automatic switching in the event of an undesired change from normal working conditions H02H7/16; emergency protective circuit arrangements for limiting excess current or voltages without disconnection H02H9/00
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• 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: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 10/0587 of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
• CPC Class Codes: H01M 6/10 with wound or folded electrodes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• 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

The invention features an electrode array (7) in which pairs of electrodes (1) are geometrically arranged so that the broadest faces of the exposed electrodes are not directly opposing to each other. Rather, the broadest facing surfaces of the electrodes in the array are parallel, adjacent, or offset at an angle. The electrode geometry of an electrode array of the invention permits electrodes to be in close proximity, thereby lowering series resistance, while minimizing the possibility for short circuits that can cause electrical leakage. An electrode array of the invention can be used in an electrochemical cell, such as a battery, e.g., a lithium battery, a capacitor, a flow-through capacitor, or a fuel cell.

Claims

1. An electrode array for use in an electrochemical cell, said array comprising:

at least one pair of oppositely-charged electrodes comprising;

a) an anode having a first anode face and a second anode face, said first anode face being broader than said second anode face; and

b) a cathode having a first cathode face and a second cathode face, said first cathode face being broader than said second cathode face, wherein said first anode face is not directly opposed to said first cathode face in said array; and

c) a dielectric material between said second anode face and said second cathode face.

2. A sheet material containing the electrode array of claim 1.

3. An electrochemical cell consisting of the sheet material of claim 2.

4. The sheet material of claim 3, wherein said sheet material is wound in a spiral.

5. The electrode array of claim 1, wherein said electrode array further comprises a planar substrate, and said electrodes are coplanar on said substrate.

6. The electrode array of claim 2, where said electrodes of said pair of electrodes are made from a carbon material.

7. The electrode array of claim 1, wherein said electrode array has a series resistance of less than 50 ohms/cm² of electrode array facing area, and an electrical leakage resistance of more than 30 ohms/cm² of electrode array facing area.

8. The electrode array of claim 1, wherein the first anode face is separated from the first cathode face by a distance of less than 3 millimeters.

9. The electrode array of claim 1, wherein the second anode face is separated from the second cathode face by a distance of more than 0.002 centimeters.

10. The electrode array of claim 1, wherein each of said electrodes in said electrode pair has a concentric spiral shape.

11. The electrode array of claim 1, wherein each of said electrodes has a surface area of greater than 10 m²/gram B.E.T.

12. A flow-through capacitor comprising the electrode array of claim 1.

13. The flow-through capacitor of claim 12, further comprising a fluid flow path for the passage of a fluid across the surface of said array.

14. A flow-through capacitor comprising the electrode array of claim 5 and a flow path for the passage of a fluid across the first anode face and across the first cathode face in said array.

15. The flow-through capacitor of claim 14, wherein said flow path comprises a porous, nonelectrically-insulating material.

16. A flow-through capacitor comprising:

a) at least two electrode arrays of claim 5; and

b) a flow path for the passage of a fluid across the first anode face and the first cathode face of the electrodes in said array, said flow path having a thickness of at least 20 micrometers in thickness.

17. A method of lowering the series resistance of an electrochemical cell, comprising the steps of:

a) providing an electrode array, said array comprising a planar substrate and at least one pair of electrodes on said planar substrate comprising an anode and a cathode, wherein said anode has a first anode face and a second anode surface, said first anode face being broader than said second anode face, and wherein said cathode has a first cathode face and a second cathode face said first cathode face being broader than said second cathode face and wherein said first anode face is not directly opposed to said first cathode face; and

b) inserting said electrode array into said electrochemical cell.

18. The method of claim 17, wherein said electrochemical cell is a flow-through capacitor.

19. The method of claim 17, wherein said electrochemical cell is a lithium battery.