Low-inductive impedance, thermally decoupled, radii-modulated electrode core
First Claim
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.
5 Assignments
0 Petitions
Accused Products
Abstract
An energy-storage device electrode core is disclosed that features relatively low-inductive impedance (and thus low equivalent series resistance (ESR)). Also disclosed is an energy-storage device electrode core that features a radii-modulated electrode core that forms extra vias to facilitate efficient heat removal away from the electrode, thus improving the performance and capabilities of an energy-storage device so equipped. The internal electrode core heat-removal vias are defined by the modulation patterns that in turn define the size and layout of the folds in the electrode, which are circumferentially collapsed about the center axis of the electrode core.
101 Citations
38 Claims
-
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, and a 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, and a 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, and wherein 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, and wherein 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. - View Dependent Claims (2, 3, 4, 5, 6, 7)
-
-
8. A method of making an energy-storage electrode core, adapted for use in an energy-storage device, comprising the steps of:
-
providing 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, and a 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; providing 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, and a 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; providing 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, and wherein 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 circumferentially collapsing said fold-zones of said current-collector foil elements about a center axis, 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, and wherein 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. - View Dependent Claims (9, 10, 11, 12, 13, 14)
-
-
15. 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 said first plurality of carbon-electrode elements define a first plurality of fold-zone regions defined between a first plurality of fold zone-demarcation regions, and a second plurality of carbon-electrode elements disposed on said second side of said first current-collector foil element, wherein said second plurality of carbon-electrode elements define a second plurality of fold-zone regions defined between a 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 said third plurality of carbon-electrode elements define a third plurality of fold-zone regions defined between a second plurality of fold zone demarcation regions, and a fourth plurality of carbon-electrode elements disposed on said second side of said second current-collector foil element, wherein said fourth plurality of carbon-electrode elements define a fourth plurality of fold-zone regions defined between a 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, and 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; 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, and 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. - View Dependent Claims (16, 17, 18, 19)
-
-
20. A method adapted for use in an energy-storage device, comprising the steps of:
-
providing 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 said first plurality of carbon-electrode elements define a first plurality of fold-zone regions defined between a first plurality of fold zone-demarcation regions, and a second plurality of carbon-electrode elements disposed on said second side of said first current-collector foil element, wherein said second plurality of carbon-electrode elements define a second plurality of fold-zone regions defined between a first plurality of fold zone demarcation regions; providing 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 said third plurality of carbon-electrode elements define a third plurality of fold-zone regions defined between a second plurality of fold zone demarcation regions, and a fourth plurality of carbon-electrode elements disposed on said second side of said second current-collector foil element, wherein said fourth plurality of carbon-electrode elements define a fourth plurality of fold-zone regions defined between a second plurality of fold zone demarcation regions; providing 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, and 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; and circumferentially collapsing said fold-zones of said current-collector foil elements about a center axis, wherein folded electrode elements are disposed in an substantially annular form, forming substantially a single loop of radial electrode folds, and 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. - View Dependent Claims (21, 22, 23, 24)
-
-
25. A thermally decoupled 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, and a 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, and a 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, and wherein 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, 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, and wherein 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 via within said energy-storage electrode core and also increase the size of said interior via from that of a uniform cylinder defined by the size of the largest fold of said energy storage electrode core. - View Dependent Claims (27, 28, 29, 30, 31)
-
-
26. The thermally decoupled energy-storage electrode core of claim 26, wherein said interior void is substantially filled with electrolyte.
-
32. A method of making a thermally decoupled energy-storage electrode core, adapted for use in an energy-storage device, comprising the steps of:
-
providing 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, and a 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; providing 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, and a 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; providing 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, and wherein 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 circumferentially collapsing said fold-zones of said current-collector foil elements about a center axis, wherein folded electrode elements are disposed in an substantially annular form, 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, and wherein 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 via within said energy-storage electrode core and also increase the size of said interior via from that of a uniform cylinder defined by the size of the largest fold of said energy storage electrode core. - View Dependent Claims (33, 34, 35, 36, 37, 38)
-
Specification