Electrical power storage devices

• US 9,525,177 B2
• Filed: 11/18/2009
• Issued: 12/20/2016
• Est. Priority Date: 11/18/2008
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Subbaraman, Ramachadran, Symanski, James, Sturgeon, Richard M., Wetzel, Dennis A., Gruenstern, Robert G., Wruck, William J., Meissner, Eberhard
• Primary Examiner(s): Crepeau, Jonathan
• Assistant Examiner(s): WILMOT, CAITLIN M
• Application Number:
  US13/129,323
• Publication Number:
  US 20110311876A1
• Time in Patent Office: 2,589 Days
• Field of Search: 429/188, 429/189, 429301-347, 429199-207, 429/208, 429209-246
• US Class Current: 1/1
• CPC Class Codes: H01G 11/24 characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/34 characterised by carbonisation or activation of carbon
• CPC Class Codes: H01G 11/36 Nanostructures, e.g. nanofibres, nanotubes or fullerenes
• CPC Class Codes: H01G 11/40 Fibres
• CPC Class Codes: H01M 10/12 Construction or manufacture
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: H01M 4/663 containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 4/668 Composites of electroconductive material and synthetic resins
• CPC Class Codes: H01M 4/68 for use in lead-acid accumulators
• CPC Class Codes: H01M 4/73 for lead-acid accumulators, e.g. frame plates
• CPC Class Codes: H01M 4/74 Meshes or woven material; Expanded metal
• CPC Class Codes: H01M 50/44 Fibrous material
• 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

An electrical storage device includes high surface area fibers (e.g., shaped fibers and/or microfibers) coated with carbon (graphite, expanded graphite, activated carbon, carbon black, carbon nanofibers, CNT, or graphite coated CNT), electrolyte, and/or electrode active material (e.g., lead oxide) in electrodes. The electrodes are used to form electrical storage devices such as electrochemical batteries, electrochemical double layer capacitors, and asymmetrical capacitors.

Claims

1. A power storage device, comprising:

a positive electrode having a grid;

a negative electrode having a grid; and

a separator separating the positive electrode from the negative electrode;

wherein at least the negative electrode or the positive electrode comprises fibers selected from both a first group consisting of trilobal cross-sectional fibers, quadrilobal cross-sectional fibers, and substantially circular cross-sectional fibers, and a second group consisting of non-straight fibers having shapes selected from the group consisting of a coiled fiber, a looped fiber, and an air entangled fiber;

the fibers being provided in an array of wicking fibers loaded with electrode active material included in the electrode;

wherein the wicking fibers constitute either a mixture of fibers selected from a first group of relatively shorter fiber pieces in addition to a second group of relatively longer fibers, or only selected from the group of relatively shorter fiber pieces.

2. The power storage device of claim 1 further comprising microfibers.

3. The power storage device of claim 1 wherein a carbon additive is provided on the fibers.

4. The power storage device of claim 3 wherein the carbon additive comprises at least one of graphite, expanded graphite, activated carbon, carbon black, carbon nanofibers, or carbon nanotubes.

5. The power storage device of claim 1 wherein the fibers are formed into a mat.

6. The power storage device of claim 1 wherein the fibers are electrical conductors.

7. The power storage device of claim 1 wherein the fibers are electrical insulators.

8. The power storage device of claim 1 wherein the fibers are fully coated in electrode active material.

9. The power storage device of claim 1, wherein the fibers form an array of wicking fibers loaded with electrode active material, the fiber array being substantially immersed in electrolyte solution.

10. The power storage device of claim 1, wherein the fibers are formed from a polymer.

11. The power storage device of claim 1, wherein the fibers further comprise a crimped fiber.

12. A battery comprising at least two grids, active material, and a scrim layer, wherein the scrim layer comprises a fiber mesh provided between the active material and one or more grids and is embedded at least partly in the active material, and wherein the scrim layer is comprised of fibers selected from a group consisting of a coiled fiber, a looped fiber, and an air entangled fiber.

13. The battery of claim 12, wherein the scrim layer is further comprised of fibers selected from a group consisting of trilobal cross-sectional fibers, quadrilobal cross-sectional fibers, and substantially circular cross-sectional fibers.

14. The battery of claim 12, further comprising a separator, wherein the scrim layer is provided between the separator and a grid.

15. The battery of claim 12 wherein the scrim layer is at least partially coated with short fibers in a flocking structure.

16. The battery of claim 12 wherein the scrim layer is a woven or non-woven mesh.

17. The battery of claim 12 wherein the scrim layer is a fiber mat.

18. The battery of claim 17 wherein the fiber mat comprises fibers made of glass.

19. The battery of claim 12 wherein the fiber mesh is comprised of a polymer.

20. The electrode of claim 19, wherein the polymer is selected from the group of polyester, polypropylene, polyethylene, and polyethylene terephthalate.

21. The battery of claim 14, further comprising a second scrim layer provided on the second grid so that the two scrim layers surround the separator.

22. The battery of claim 12, wherein the scrim layer is formed of a woven or non-woven mesh in a pattern to adjust to the ability of the scrim to adhere and/or support the active material.

23. A power storage device, comprising:

at least one positive electrode;

at least one negative electrode; and

a mat comprised of a plurality of fibers, wherein the

fibers are selected from both of two groups, the first group selected from the group consisting of trilobal cross-sectional fibers, substantially circular cross-sectional fibers, and quadrilobal cross-sectional fibers; and

the second group selected from the group consisting of a coiled fiber, a looped fiber, an air entangled fiber and combinations of the foregoing, and wherein the mat is woven.

24. The power storage device of claim 23 wherein the mat further comprises microfibers.

25. The power storage device of claim 23 wherein an additive is provided on the fibers.

26. A power storage device, comprising:

at least one positive electrode;

at least one negative electrode; and

a mat comprised of a plurality of fibers, wherein the

fibers are selected from both of two groups, the first group selected from the group consisting of trilobal cross-sectional fibers, substantially circular cross-sectional fibers, and quadrilobal cross-sectional fibers; and

the second group selected from the group consisting of a coiled fiber, a looped fiber, an air entangled fiber and combinations of the foregoing, and wherein the fibers further comprise a crimped fiber.

27. The power storage device of claim 26 wherein the mat further comprises microfibers.

28. The power storage device of claim 26 wherein an additive is provided on the fibers.