Electrochemical energy storage devices and manufacturing methods

• US 10,312,028 B2
• Filed: 06/25/2015
• Issued: 06/04/2019
• Est. Priority Date: 06/30/2014
• Status: Active Grant

• Current Assignee: Kyocera AVX Components Corporation (Kyocera Corporation)
• Original Assignee: AVX Corporation (Kyocera Corporation)
• Inventors: Rawal, Bharat, Eggerding, Carl L., Knopsnyder, Bob
• Primary Examiner(s): Ha, Nguyen T
• Application Number:
  US14/749,785
• Publication Number:
  US 20150380175A1
• Time in Patent Office: 1,440 Days
• CPC Class Codes: H01G 11/12 Stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/60 characterised by the solvent
• CPC Class Codes: H01G 11/72 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/74 Terminals, e.g. extensions of current collectors
• CPC Class Codes: H01G 11/76 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/80 Gaskets; Sealings
• CPC Class Codes: H01G 11/82 Fixing or assembling a capacitive element in a housing, e.g. mounting electrodes, current collectors or terminals in containers or encapsulations
• CPC Class Codes: H01G 11/84 Processes for the manufacture of hybrid or EDL capacitors, or components thereof
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

An ultra-thin electrochemical energy storage device is provided which utilizes electrode material with multi-layer current collectors and with an organic electrolyte between the electrodes. Multiple cells may be positioned in a plurality of stacks and all of the cells may be in series, parallel or some combination thereof. The energy storage device can be constructed at less than 0.5 millimeters thick and exhibit very low ESR and higher temperature range capabilities.

Claims

1. An ultra-thin electrochemical energy storage device, comprising:

a pair of respective internal electrodes with electrolyte;

a separator layer between said respective electrodes;

a pair of respective current collectors, with one each of said current collectors respectively outside each of said electrodes; and

a case surrounding said current collectors, and having a respective pair of terminals connected respectively with said current collectors;

wherein the contents of said case have a thickness down to less than 0.5 millimeters; and

wherein said device has a resistivity of no more than about 1.5 Ω

·

cm² of electrode area.

2. An ultra-thin electrochemical energy storage device as in claim 1, wherein said case has a moisture content of no more than about 10 ppm.

3. An ultra-thin electrochemical energy storage device as in claim 1, wherein said electrolyte comprises an organic electrolyte.

4. An ultra-thin electrochemical energy storage device as in claim 1, wherein said electrolyte includes at least some of propylene carbonate.

5. An ultra-thin electrochemical energy storage device as in claim 1, wherein:

said device has a temperature operational range rating of −

40°

to 70°

C.

6. An ultra-thin electrochemical energy storage device as in claim 1, further comprising a plurality of said devices arranged as multiple cells positioned in a plurality of stacks configured in one of series or parallel connections, or combinations thereof.

7. An ultra-thin electrochemical energy storage device as in claim 1, wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

8. An ultra-thin electrochemical energy storage device as in claim 1, wherein:

said electrolyte comprises an organic electrolyte; and

said device comprises an electrochemical double layer (ECDL) capacitor having a capacitance density of at least about 10 Farads per cc of active electrode volume.

9. An ultra-thin electrochemical energy storage device as in claim 8, wherein:

said electrolyte has a boiling point over 200°

C.;

said case further includes thermally stable sealant materials; and

said capacitor has a temperature operational half-voltage range rating of up to 90°

C.

10. An ultra-thin electrochemical energy storage device as in claim 8, wherein:

said organic electrolyte includes at least some of propylene carbonate; and

said case has dimensions of about 50 mm long×

40 mm wide×

0.5 mm thick, and maintains dimensional stability at up to about 105°

C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ

.

11. An ultra-thin, ultra-low ESR supercapacitor, comprising:

a pair of respective internal electrodes with organic electrolyte;

an ultra-thin separator layer between said respective electrodes;

a pair of respective multi-layer current collectors, with one each of said current collectors respectively outside each of said electrodes; and

a case surrounding said current collectors, and having a respective pair of terminals connected respectively with said current collectors;

wherein the contents of said case have a thickness down to less than 0.5 millimeters, and a moisture content of no more than about 10 ppm, and

said supercapacitor has a resistivity of no more than about 1.5 Ω

·

cm² of electrode area, capacitance density of at least about 10 Farads per cc of active electrode volume, and a temperature operational range rating of −

40°

to 70°

C.

12. A supercapacitor as in claim 11, wherein said supercapacitor comprises a carbon double layer capacitor with a voltage rating of 4.2 volts, and a temperature operational half-voltage range rating of −

40°

to 90°

C.

13. A supercapacitor as in claim 11, wherein said organic electrolyte includes at least some of propylene carbonate.

14. A supercapacitor as in claim 13, wherein said case has dimensions of about 50 mm long×

40 mm wide×

0.5 mm thick, and maintains dimensional stability at up to about 105°

C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ

.

15. A supercapacitor as in claim 11, further comprising a plurality of said supercapacitors arranged as multiple cells positioned in a plurality of stacks.

16. A supercapacitor as in claim 15, wherein said stacks of multiple cells are arranged in one of series or parallel connections, or combinations thereof.

17. A supercapacitor as in claim 11, wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

18. A supercapacitor as in claim 11, wherein:

said electrolyte has a boiling point over 200°

C.;

said case further includes thermally stable sealant materials; and

said supercapacitor has a temperature operational half-voltage range rating of up to 90°

C.

19. Methodology for manufacturing an ultra-thin electrochemical energy storage device, comprising:

providing a pair of respective internal electrodes with electrolyte, and with a separator layer between such respective electrodes;

providing a pair of respective current collectors, with one each of such current collectors respectively outside each of such electrodes; and

surrounding such current collectors with a case having a respective pair of terminals connected respectively with such current collectors;

wherein the contents of such case have a thickness down to less than 0.5 millimeters; and

wherein said device has a resistivity of no more than about 1.5 Ω

·

cm² of electrode area.

20. Methodology as in claim 19, wherein said methodology is performed in a controlled environment having a moisture content of no more than about 10 ppm.

21. Methodology as in claim 19, wherein said electrolyte comprises an organic electrolyte.

22. Methodology as in claim 19, wherein said electrolyte includes at least some of propylene carbonate.

23. Methodology as in claim 19, wherein:

said device has a temperature operational range rating of −

40°

to 70°

C.

24. Methodology as in claim 19, further comprising arranging a plurality of said devices as multiple cells positioned in a plurality of stacks configured in one of series or parallel connections, or combinations thereof, for selectively achieving desired capacitance and/or operational voltage levels.

25. Methodology as in claim 19, wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

26. Methodology as in claim 19, wherein:

said electrolyte comprises an organic electrolyte; and

said device comprises an electrochemical double layer (ECDL) capacitor having a capacitance density of at least about 10 Farads per cc of active electrode volume.

27. Methodology as in claim 26, wherein:

said electrolyte has a boiling point over 200°

C.;

said case further includes thermally stable sealant materials; and

said capacitor has a temperature operational half-voltage range rating of up to 90°

C.

28. Methodology as in claim 26, wherein:

said organic electrolyte includes at least some of propylene carbonate; and

said case has dimensions of about 50 mm long×

40 mm wide×

0.5 mm thick, and maintains dimensional stability at up to about 105°

C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ

.

29. Methodology for making an ultra-thin, ultra-low ESR supercapacitor, comprising:

providing a pair of respective internal electrodes with organic electrolyte, and with an ultra-thin separator layer between such respective electrodes;

providing a pair of respective multi-layer current collectors, with one each of such current collectors respectively outside each of such electrodes; and

surrounding such current collectors with a case having a respective pair of terminals connected respectively with such current collectors;

wherein the contents of said case have a thickness down to less than 0.5 millimeters, and said methodology is performed in a controlled environment having a moisture content of no more than about 10 ppm, and

said supercapacitor has a resistivity of no more than about 1.5 Ω

·

cm² of electrode area, capacitance density of at least about 10 Farads per cc of active electrode volume, and a temperature operational range rating of −

40°

to 70°

C.

30. Methodology as in claim 29, wherein said supercapacitor comprises a carbon double layer capacitor with a voltage rating of 4.2 volts, a temperature operational half-voltage range rating of −

40°

to 90°

C.

31. Methodology as in claim 29, wherein said organic electrolyte includes at least some of propylene carbonate.

32. Methodology as in claim 31, wherein said case has dimensions of about 50 mm long×

40 mm wide×

0.5 mm thick, and maintains dimensional stability at up to about 105°

C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ

.

33. Methodology as in claim 29, further comprising a plurality of said supercapacitors arranged as multiple cells positioned in a plurality of stacks, for selectively achieving desired capacitance and/or operational voltage levels.

34. Methodology as in claim 33, wherein said stacks of multiple cells are arranged in one of series or parallel connections, or combinations thereof, for achieving hybrid packs of a battery or batteries combined with a capacitor or capacitors in a single integrated product.

35. Methodology as in claim 29, wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

36. Methodology as in claim 29, wherein:

said electrolyte has a boiling point over 200°

C.;

said case further includes thermally stable sealant materials; and

said supercapacitor has a temperature operational half-voltage range rating of up to 90°

C.