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Low-inductive impedance, thermally decoupled, radii-modulated electrode core

  • US 20100273061A1
  • Filed: 12/24/2009
  • Published: 10/28/2010
  • Est. Priority Date: 09/29/2006
  • Status: Active Grant
First Claim
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1. An energy-storage electrode core, adapted for use in an energy-storage device, comprising:

  • a first current-collector foil element having a first side and a second side, comprising;

    a first plurality of carbon-electrode elements disposed on said first side of said first current-collector foil element,wherein the spans of said first plurality of carbon-electrode elements are modulated in a pattern that defines a first plurality of fold-zone regions defined between a first plurality of fold zone-demarcation regions, anda second plurality of carbon-electrode elements disposed on said second side of said first current-collector foil element,wherein the spans of said second plurality of carbon-electrode elements are modulated in a pattern that matches and adds to said first plurality of fold-zone regions defined between said first plurality of fold zone-demarcation regions;

    a second current-collector foil element having a first side and a second side, comprising;

    a third plurality of carbon-electrode elements disposed on said first side of said second current-collector foil element,wherein the spans of said third plurality of carbon-electrode elements are modulated in a pattern that defines a third plurality of fold-zone regions defined between a second plurality of fold zone-demarcation regions, anda fourth plurality of carbon-electrode elements disposed on said second side of said second current-collector foil element,wherein the spans of said fourth plurality of carbon-electrode elements are modulated in a pattern that matches and adds to said third plurality of fold-zone regions defined between said second plurality of fold zone-demarcation regions;

    a separator element, having a front side and a back side,wherein the front side of said separator element is affixed to said second side of said first current-collector foil element,wherein the back side of said separator element is affixed to said first side of said second current-collector foil element,wherein said separator element prevents said first current-collector foil element from electronically shorting to said second current-collector foil element, while still allowing ionic current flow therebetween, andwherein said modulation patterns of said plurality of fold-zone regions of said first plurality of fold-zone demarcation regions and said modulation patterns of said plurality of fold-zone regions of said second plurality of fold-zone demarcation regions are aligned such that the modulation patterns match in each fold zone; and

    a center axis about which said fold-zones of said current-collector foil elements are circumferentially collapsed,wherein folded electrode elements are disposed in an substantially annular form, forming substantially a single loop of radial electrode folds,wherein said pluralities of fold-zone demarcation regions are approximately laterally and co-axially aligned with respect to said first and second current-collector foils,wherein, relative to said center axis of said energy-storage electrode core, all of the distal electrode folds are situated substantially equidistant from said center axis,wherein, relative to said center axis of said energy-storage electrode core, the distance between the inner electrode folds and said center axis is a function of said modulation pattern, said modulation pattern which defines the length of each fold in said energy storage electrode core, andwherein said distance between the inner electrode folds (that are defined from said modulation pattern) and said center axis define the size and shape of the interior void within said energy-storage electrode core and also increase the size of said interior void from that of a uniform cylinder defined by the size of the largest fold of said energy-storage electrode core.

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