Structural energy storage assemblies and methods for production thereof

• US 9,017,854 B2
• Filed: 08/29/2011
• Issued: 04/28/2015
• Est. Priority Date: 08/30/2010
• Status: Active Grant

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Fleischer, Corey Adam
• Primary Examiner(s): Huff, Mark F
• Assistant Examiner(s): WILLS, MONIQUE M
• Application Number:
  US13/220,597
• Publication Number:
  US 20120052363A1
• Time in Patent Office: 1,338 Days
• Field of Search: 429/149, 429/231.8, 29/254.1, 295/921, 361/500, 361/502, 977/742, 977/948
• US Class Current: 429/149
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: H01G 11/10 Multiple hybrid or EDL capacitors, e.g. arrays or modules housings, cases, encapsulations or mountings thereof H01G11/78
• CPC Class Codes: H01G 11/22 Electrodes
• 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: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/84 Processes for the manufacture of hybrid or EDL capacitors, or components thereof
• CPC Class Codes: H01G 9/0029 Processes of manufacture
• CPC Class Codes: H01G 9/042 characterised by the material H01G11/22 takes precedence
• CPC Class Codes: H01G 9/08 Housing; Encapsulation
• CPC Class Codes: H01G 9/26 Structural combinations of electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices with each other
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/218 characterised by the material
• CPC Class Codes: H01M 50/509 characterised by the type of connection, e.g. mixed connections
• CPC Class Codes: H01M 50/519 comprising printed circuit boards [PCB]
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 2201/10015 Non-printed capacitor
• CPC Class Codes: H05K 2201/10037 Printed or non-printed battery
• CPC Class Codes: H05K 3/32 electrically connecting electric components or wires to printed circuits
• 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
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/43 : Electric condenser making
• CPC Class Codes: Y10T 29/49002 : Electrical device making
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making

Abstract

Described herein are multi-functional composite materials containing energy storage assemblies that can be significantly resistant to tension/compression stress. The energy storage assemblies can contain at least one energy storage layer that contains an insulating layer having a plurality of openings arranged in a spaced apart manner, and a plurality of energy storage devices, each energy storage device being contained within one of the openings. The energy storage devices can be electrically connected to one another. The energy storage layer can contain a support material upon which electrical connections are formed. One or more energy storage layers can be disposed between two or more stress carrying layers to form an energy storage assembly that can have significant resistance to tension/compression stress. Energy storage devices suitable for use in the energy storage assemblies can include, for example, batteries, capacitors and/or supercapacitors. Methods for producing the energy storage assemblies are also described.

Claims

1. An energy storage assembly comprising:

at least one energy storage layer comprising;

an insulating layer having a plurality of openings arranged in a spaced apart manner;

a plurality of energy storage devices, each energy storage device being contained within one of said openings, wherein at least some of the energy storage devices contain carbon nanotube-infused fibers; and

a support material upon which the plurality of energy storage devices is disposed,

wherein the plurality of energy storage devices are electrically connected to one another through electrical connections on the support material.

2. The energy storage assembly of claim 1, wherein the insulating layer is disposed on the support material.

3. The energy storage assembly of claim 1, wherein at least some of the energy storage devices are electrically connected to one another in parallel.

4. The energy storage assembly of claim 3, wherein at least some of the energy storage devices are electrically connected to one another in series.

5. The energy storage assembly of claim 1, wherein the insulating layer comprises a material selected from the group consisting of a polymer and a fiber-reinforced polymer composite.

6. The energy storage assembly of claim 1, wherein at least some of the energy storage devices comprise batteries.

7. The energy storage assembly of claim 1, wherein at least some of the energy storage devices comprise capacitors or supercapacitors.

8. The energy storage assembly of claim 1, wherein at least some of the energy storage devices contain carbon nanotubes.

9. The energy storage assembly of claim 1, wherein carbon nanotubes of the carbon-nanotube infused fibers are at least partially covered with a coating selected from the group consisting of polypyrrole, MnO₂, RuO₂, and combinations thereof.

10. The energy storage assembly of claim 1, further comprising:

at least one stress carrying layer in contact with the at least one energy storage layer.

11. The energy storage assembly of claim 10, wherein the at least one energy storage layer is disposed between at least two stress carrying layers.

12. The energy storage assembly of claim 11, wherein the at least two stress carrying layers each comprise a fiber-reinforced polymer composite.

13. The energy storage assembly of claim 1, wherein the plurality of energy storage devices are arranged in a grid structure in the at least one energy storage layer.

14. The energy storage assembly of claim 1, wherein a height of the insulating layer is at least that of the energy storage devices.

24. The energy storage assembly of claim 1, wherein:

the support material comprises a layer of material upon which the plurality of energy storage devices is disposed, and

each of the plurality of energy storage devices is in contact with the layer of support material.

25. The energy storage assembly of claim 1, wherein the plurality of storage devices are electrically connected to one another through electrical connections printed on the layer of material.

15. An energy storage assembly comprising:

at least two stress carrying layers; and

at least one energy storage layer disposed between the at least two stress carrying layers, the at least one energy storage layer comprising;

a support material;

an insulating layer having a plurality of openings arranged in a spaced apart manner; and

a plurality of energy storage devices disposed on the support material, the plurality of energy storage devices being electrically connected to one another through electrical connections on the support material, each energy storage device being contained within one of said openings, wherein at least some of the energy storage devices contain carbon nanotube-infused fibers.

16. The energy storage assembly of claim 15, wherein the at least one energy storage layer comprises up to about 90% of a thickness of the energy storage assembly.

17. The energy storage assembly of claim 15, wherein the insulating layer comprises a material selected from the group consisting of a polymer and a fiber-reinforced polymer composite.

18. The energy storage assembly of claim 15, wherein each energy storage device is enveloped with a casing;

and

wherein the casing comprises the insulating layer.

19. The energy storage assembly of claim 15, wherein each of said openings comprise a hole in the insulating layer.

20. The energy storage assembly of claim 15, wherein at least some of the energy storage devices comprise batteries.

21. The energy storage assembly of claim 15, wherein at least some of the energy storage devices comprise capacitors or supercapacitors.

22. The energy storage assembly of claim 15, wherein at least some of the energy storage devices contain carbon nanotubes.

23. The energy storage assembly of claim 15, wherein the plurality of energy storage devices are arranged in a grid structure in the at least one energy storage layer.