Spiral wound electrical devices containing carbon nanotube-infused electrode materials and methods and apparatuses for production thereof

• US 8,665,581 B2
• Filed: 03/02/2011
• Issued: 03/04/2014
• Est. Priority Date: 03/02/2010
• Status: Active Grant

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Fleischer, Corey Adam, Shah, Tushar K., Hetzel, Lawrence P., Malecki, Harry C.
• Primary Examiner(s): Ha, Nguyen T
• Application Number:
  US13/039,025
• Publication Number:
  US 20110242731A1
• Time in Patent Office: 1,098 Days
• Field of Search: 361/502, 361503-504, 361508-512, 361516-519, 361523-525, 361528-529
• US Class Current: 361/502
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/36 Nanostructures, e.g. nanofibres, nanotubes or fullerenes
• 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

Electrical devices having electrodes containing carbon nanotubes infused to a substrate are described herein. The electrical devices contain at least a first electrode material containing a first plurality of carbon nanotubes infused to a first substrate and a second electrode material containing a second plurality of carbon nanotubes infused to a second substrate. The first electrode material and the second electrode material are wound in a spiral configuration about a central axis. The electrical devices can be supercapacitors, which also contain at least an electrolyte in contact with the first electrode material and the second electrode material, and a first separator material disposed between the first electrode material and the second electrode material. Methods and apparatuses for making the electrical devices are also disclosed herein.

Claims

1. An electrical device comprising:

a first electrode material comprising a first plurality of carbon nanotubes grown directly on, and infused to, a first substrate; and

a second electrode material comprising a second plurality of carbon nanotubes infused to a second substrate;

wherein the first electrode material and the second electrode material are wound in a spiral configuration about a central axis.

2. The electrical device of claim 1, further comprising:

an electrolyte in contact with the first electrode material and the second electrode material; and

a first separator material disposed between the first electrode material and the second electrode material;

wherein the first separator material is permeable to ions of the electrolyte.

3. The electrical device of claim 2, wherein the electrical device comprises a supercapacitor.

4. The electrical device of claim 2, wherein the electrolyte comprises an inorganic electrolyte.

5. The electrical device of claim 2, wherein the electrolyte comprises an organic electrolyte.

6. The electrical device of claim 2, further comprising:

an insulator material;

wherein the insulator material is not adjacent to the first separator material.

7. The electrical device of claim 2, further comprising:

a second separator material;

wherein the second separator material is not adjacent to the first separator material.

8. The electrical device of claim 2, wherein an edge of the first electrode material and an edge of the second electrode material are offset from one another.

9. The electrical device of claim 1, wherein the first substrate and the second substrate comprise a plurality of continuous fibers.

10. The electrical device of claim 9, wherein the continuous fibers are selected from the group consisting of carbon fibers, metal fibers and combinations thereof.

11. The electrical device of claim 1, wherein the first substrate and the second substrate comprise a form selected from the group consisting of a metal sheet, a metal foil, a metal film, a graphite sheet, a graphite film, a woven sheet of continuous fibers, a non-woven sheet of continuous fibers, a ply of continuous fibers, a mat of continuous fibers, a ribbon of continuous fibers, a tape of continuous fibers, and combinations thereof.

12. The electrical device of claim 1, wherein the first substrate and the second substrate are electrically conductive before being infused with carbon nanotubes.

13. The electrical device of claim 1, further comprising:

an insulator material coating the outermost surface of the spiral configuration.

14. The electrical device of claim 1, further comprising:

a first electrode terminal in contact with the first electrode material; and

a second electrode terminal in contact with the second electrode material.

15. The electrical device of claim 1, wherein the carbon nanotubes are substantially perpendicular to the surface of the substrate to which they are infused.

16. The electrical device of claim 1, wherein the first plurality of carbon nanotubes are grown directly on the first substrate by transporting the first substrate through a carbon nanotube growth reactor.