Multi-electrode double layer capacitor having hermetic electrolyte seal

• US 6,842,330 B2
• Filed: 09/06/2002
• Issued: 01/11/2005
• Est. Priority Date: 08/18/1999
• Status: Expired due to Term

• Current Assignee: Tesla Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Nanjundiah, Chenniah, Crawford, Robert W., Dispennette, John M., Blank, Edward, Farahmandi, C. Joseph
• Primary Examiner(s): Nguyen, Chau N.
• Assistant Examiner(s): THOMAS, ERIC W
• Application Number:
  US10/236,793
• Publication Number:
  US 20030030969A1
• Time in Patent Office: 858 Days
• Field of Search: 361/502, 361503-507, 361516-518
• US Class Current: 361/502
• CPC Class Codes: H01G 11/58 Liquid electrolytes
• CPC Class Codes: H01G 11/72 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/80 Gaskets; Sealings
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal. And an electrolyte solution saturates the first and second electrodes comprising carbon and is substantially contained by the case and the electrically insulating hermitic seal such that an influx of impurities into the electrolyte solution is substantially inhibited by the case and the electrically insulating hermetic seal.

Claims

1. A long life double layer capacitor comprising:

a case;

a first terminal;

an electrically insulating hermetic seal interposed between the first terminal and the case;

a first current collector foil electrically coupled to an interior portion of the first terminal;

a first electrode, wherein the first electrode comprises carbon, the first electrode being juxtaposed against one side of the first current collector foil;

a porous separator juxtaposed against another side of the first electrode;

a second electrode, wherein the second electrode comprises carbon, one side of the second electrode being juxtaposed against the porous separator, wherein the porous separator is interposed between the first electrode and the second electrode;

a second current collector foil, the second current collector foil being juxtaposed against another side of the second electrode;

a second terminal electrically coupled to the second current collector foil; and

an electrolyte solution saturating the first electrode and the second electrode, wherein the electrolyte solution is substantially contained by the case and the electrically insulating hermetic seal, and wherein influx of impurities into the electrolyte solution is substantially inhibited by the case and the electrically insulating hermetic seal.

2. The long life double layer capacitor of claim 1 wherein said electrically insulating hermetic seal comprises glass.

3. The long life double layer capacitor of claim 2 wherein said first terminal comprises molybdenum.

4. The long life double layer capacitor of claim 2 wherein said first terminal comprises platinum coated molybdenum.

5. The long life double layer capacitor of claim 2 wherein said case comprises:

a header plate, wherein the electrically insulating hermetic seal is interposed between the first terminal and the header plate; and

a can, wherein the header plate is welded to the can.

6. The long life double layer capacitor of claim 2 wherein said electrically insulating hermetic seal comprises one or more of the group consisting of silica, boron oxide, alumina, potassium oxide, sodium oxide, and lithium oxide.

7. The long life double layer capacitor of claim 1 wherein said case comprises a conductive case.

8. The long life double layer capacitor of claim 7 wherein said conductive case comprises stainless steel.

9. The long life double layer capacitor of claim 1 wherein said porous separator can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

10. The long life double layer capacitor of claim 9 wherein said porous separator material comprises polytetrafluoroethylene (PTFE).

11. The long life double layer capacitor of claim 1 wherein said case can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

12. The long life double layer capacitor of claim 1 wherein said electrolyte solution comprises a selected solvent and a selected salt.

13. The long life double layer capacitor of claim 12 wherein said selected solvent comprises acetonitrile or propylene carbonate.

14. The long life double layer capacitor of claim 12 wherein said selected salt comprises tetraethylammonium tetraflouraborate or triethylmethylammonium tetraflouraborate.

15. The long life double layer capacitor of claim 1 wherein said electrically insulating hermetic seal can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

16. The long life double layer capacitor of claim 1 further comprising one or more crimps formed in said case for exerting a modest, constant pressure on an electrode assembly contained within said case.

17. A long life double layer capacitor comprising:

a hermetically sealed case;

a plurality of electrodes, each having a first side, wherein each of the plurality of electrodes comprises carbon;

a plurality of current collector foils each juxtaposed against a respective one of the plurality of electrodes against said first side;

a porous separator material positioned between respective ones of the plurality of electrodes; and

a non-aqueous electrolyte solution saturating said plurality of electrodes, wherein a multi-electrode, single cell device is formed, and wherein influx of impurities into the non-aqueous electrolyte solution is substantially inhibited by the hermetically sealed case.

18. The long life double layer capacitor of claim 17 wherein said hermetically sealed case comprises a glass-to-metal seal.

19. The long life double layer capacitor of claim 18 wherein said glass-to-metal seal can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

20. The long life double layer capacitor of claim 18 wherein a first terminal is coupled to at least one of said plurality of electrodes through said glass-to-metal seal.

21. The long life double layer capacitor of claim 20 wherein said first terminal comprises molybdenum.

22. The long life double layer capacitor of claim 21 further comprising:

a second terminal wherein said second terminal is electrically coupled to said case.

23. The long life double layer capacitor of claim 21 wherein said first terminal further comprises platinum.

24. The long life double layer capacitor of claim 21 wherein said first terminal comprises a platinum coated molybdenum wire.

25. The long life double layer capacitor of claim 17 wherein said electrolyte solution comprises a selected solvent and a selected salt.

26. The long life double layer capacitor of claim 25 wherein said selected solvent comprises acetonitrile or propylene carbonate.

27. The long life double layer capacitor of claim 26 wherein said selected salt comprises tetraethylammonium tetraflouraborate or triethylmethylammonium tetraflouraborate.

28. The long life double layer capacitor of claim 17 wherein said hermetically sealed case can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

29. The long life double layer capacitor of claim 17 wherein said porous separator material can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

30. The long life double layer capacitor of claim 29 wherein said porous separator material comprises polytetrafluoroethylene (PTFE).

31. The long life double layer capacitor of claim 17 wherein said double layer capacitor can withstand exposure to temperatures of up to 250°

C. for periods of up to 5 minutes.

32. The long life double layer capacitor of claim 17 further comprising one or more crimps formed in said hermetically sealed case for exerting a modest, constant pressure on said plurality of electrodes, said plurality of current collector foils, and said porous separator material contained within said hermetically sealed case.