Structural energy storage assemblies and methods for production thereof

• US 9,907,174 B2
• Filed: 12/18/2014
• Issued: 02/27/2018
• 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:
  US14/576,080
• Publication Number:
  US 20160330842A1
• Time in Patent Office: 1,167 Days
• 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. A method comprising:

forming a plurality of electrical connections on a surface of a support material;

after forming the plurality of electrical connections, disposing a plurality of energy storage devices on the support material in a spaced apart manner, wherein at least one of the plurality of energy storage devices comprises carbon nanotube-infused fibers; and

after disposing the plurality of energy storage devices, disposing an insulating layer around and between each of the plurality of energy storage devices on the support material, thereby forming an energy storage layer.

2. The method of claim 1, wherein, prior to being disposed around the plurality of energy storage devices, the insulating layer is preformed with a plurality of spaced apart openings matching a spacing of the plurality of energy storage devices.

3. The method of claim 1, further comprising:

electrically connecting the plurality of energy storage devices using the plurality of electrical connections.

4. The method of claim 1, further comprising:

placing at least one energy storage layer between at least two stress carrying layers, each stress carrying layer comprising a fiber-reinforced polymer composite.

5. The method of claim 4, wherein placing at least one energy storage layer comprises:

cutting the at least one energy storage layer into a plurality of strips; and

placing at least one of the plurality of strips between the at least two stress carrying layers.

6. The method of claim 4, wherein placing at least one energy storage layer comprises winding the at least one energy storage layer over a male mould.

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

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

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