×

Utilization of poly(ethylene terephthalate) plastic and composition-modified barium titanate powders in a matrix that allows polarization and the use of integrated-circuit technologies for the production of lightweight ultrahigh electrical energy storage units (EESU)

  • US 7,466,536 B1
  • Filed: 08/13/2004
  • Issued: 12/16/2008
  • Est. Priority Date: 08/13/2004
  • Status: Expired due to Fees
0
Associated Cases
0
Associated Defendants
0
Product Citations
0
Petitions
61
Forward Citations
1
Assignment
First Claim
Patent Images

1. An electrical-energy-storage unit fabricated by a method, the method comprising:

  • a) cooling poly(ethylene terephthalate) plastic pellets to −

    150°

    C. by a cooling system;

    b) feeding the poly(ethylene terephthalate) plastic pellets at −

    150°

    C. into a jet pulverizing mill to pulverize the poly(ethylene terephthalate) plastic pellets to a submicron size poly(ethylene terephthalate) plastic powder;

    c) cooling aluminum powder to −

    150°

    C.;

    d) feeding the aluminum powder into a jet pulverizing mill to pulverize the aluminum powder to a submicron size;

    e) forming a first screen-printing ink from alumina-coated composition-modified barium titanate ceramic powder, the poly(ethylene terephthalate) plastic powder, and a binder, the binder including nitrocellulose, glycerol, and isopropyl alcohol;

    f) forming a second screen-printing ink from the poly(ethylene terephthalate) plastic powder and the binder;

    g) forming a third screen-printing ink from the aluminum powder and the binder;

    h) wherein each ink is independently mixed in an associated tank that has the capability to mechanical mix, provide ultrasonic agitation, and high-impact multiple oppositely directed streams;

    i) independently delivering each ink from its associated tank to an associated station of a screen-printing system via high-pressure pumps to a line manifold with several equal-spaced holes located at an edge of each printing screen;

    j) screen-printing a basis layer of the second screen-printing ink onto a flat polytetrafluoroethylene coated stainless steel plate;

    k) screen-printing a second layer of the third screen-printing ink via a stencil for an electrode layer;

    l) screen-printing as part of the second layer and surrounding the electrode layer on three sides, the second screen-printing ink via a stencil onto the first layer;

    m) screen-printing a third layer of the first screen-printing ink via a stencil onto the second layer, the third layer serving as an active dielectric layer;

    n) screen-printing as part of the third layer and surrounding the active dielectric layer on four sides, the second screen-printing ink via a stencil onto the second layer;

    o) screen-printing a fourth layer of the third screen-printing ink via a stencil onto the third layer, the fourth layer serving as an opposite electrode to the active dielectric layer;

    p) screen-printing as part of the fourth layer and surrounding the opposite electrode on three sides, the second screen-printing ink via a stencil onto the third layer;

    q) repeating steps m through p 100 times to fabricate multilayer sheets;

    r) after each screen-printing, processing the multilayer sheets by an inline oven which has multiple temperature zones that range from 40°

    C. to 150°

    C. at a speed, such that the through times are 10 seconds for the electrode layers and 60 seconds for the dielectric layers;

    s) dicing the multilayer sheets into individual elements;

    t) placing the elements into indentations of coated stainless steel trays and inserting the trays into a hot isostatic pressing oven to process the elements at a temperature of 180°

    C. and a pressure of 100 bar with a total time of 45 minutes;

    u) bonding together ten of said elements with an adhesive having a curing temperature of 80°

    C. for a duration of 10 minutes to create a component;

    v) abrasively cleaning the component to expose alternately offset interleaved aluminum electrodes to each of the two opposite sides of the component and bonding aluminum end caps to the component sides that have the exposed electrodes;

    w) placing the component into an oven and ramping the temperature to 180°

    C. over 20 minutes, applying +2000 V to a first set of the electrodes and −

    2000 V to a second set of the electrodes for 5 minutes;

    x) assembling the component into a first level array;

    y) stacking a number of the first level arrays on top of one another; and

    z) packaging the array stack into the electrical energy storage unit.

View all claims
  • 1 Assignment
Timeline View
Assignment View
    ×
    ×