Electrical-energy-storage unit (EESU) utilizing ceramic and integrated-circuit technologies for replacement of electrochemical batteries

• US 7,595,109 B2
• Filed: 04/10/2006
• Issued: 09/29/2009
• Est. Priority Date: 04/12/2001
• Status: Expired due to Term

• Current Assignee: Eestor Inc. (FuelPositive Corp.)
• Original Assignee: Eestor Inc. (FuelPositive Corp.)
• Inventors: Nelson, Carl Walter, Weir, Richard Dean
• Primary Examiner(s): KILIMAN, LESZEK B
• Application Number:
  US11/400,875
• Publication Number:
  US 20060210779A1
• Time in Patent Office: 1,268 Days
• Field of Search: 428403-407, 428/400, 428/209, 429/247, 296/231, 296/235
• US Class Current: 428/403
• CPC Class Codes: C03C 1/008 for the production of films or coatings
• CPC Class Codes: C04B 2235/36 Glass starting materials for making ceramics, e.g. silica glass
• CPC Class Codes: C04B 2235/6025 Tape casting, e.g. with a doctor blade
• CPC Class Codes: C04B 35/468 based on barium titanates
• CPC Class Codes: C04B 35/62813 Alumina or aluminates
• CPC Class Codes: C04B 35/62894 with more than one coating layer
• CPC Class Codes: C04B 35/62897 Coatings characterised by their thickness
• CPC Class Codes: H01G 4/1227 based on alkaline earth titanates
• CPC Class Codes: H01G 4/30 Stacked capacitors H01G4/33 takes precedence
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49115 including coating or impregnating
• CPC Class Codes: Y10T 428/24917 including metal layer
• CPC Class Codes: Y10T 428/2991 Coated
• CPC Class Codes: Y10T 428/2993 Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/2995 Silane, siloxane or silicone coating
• CPC Class Codes: Y10T 428/2996 Glass particles or spheres
• CPC Class Codes: Y10T 428/2998 including synthetic resin or polymer

Abstract

An electrical-energy-storage unit (EESU) has as a basis material a high-permittivity composition-modified barium titanate ceramic powder. This powder is double coated with the first coating being aluminum oxide and the second coating calcium magnesium aluminosilicate glass. The components of the EESU are manufactured with the use of classical ceramic fabrication techniques which include screen printing alternating multilayers of nickel electrodes and high-permittivitiy composition-modified barium titanate powder, sintering to a closed-pore porous body, followed by hot-isostatic pressing to a void-free body.

Claims

1. An article of manufacture comprising:

first and second electrodes; and

a dielectric layer located between the first and second electrodes, the dielectric layer including high-permittivity ceramic powder particles coated with a first layer of high dielectric breakdown material and isostatically pressed together, wherein the first layer of high dielectric breakdown material comprises material different from the high-permittivity ceramic powder particles, wherein the high-permittivity ceramic powder particles comprise composition-modified barium titanate, wherein the first layer of high dielectric breakdown material comprises alumina.

2. The article of manufacture of claim 1, further comprising a second layer of high breakdown dielectric material, wherein the second layer of high dielectric breakdown material is coated over the first layer of high dielectric breakdown material and comprises material different from the high-permittivity ceramic powder particles and the first layer of high dielectric breakdown material.

3. The article of manufacture of claim 2, wherein the second layer of high dielectric breakdown material is a glass.

4. The article of manufacture of claim 1, wherein at least one of the first and second electrodes includes a nickel electrode.

5. The article of manufacture of claim 2, wherein the second layer of high dielectric breakdown material includes a calcium magnesium aluminosilicate glass.

6. The article of manufacture of claim 2, wherein the second layer of high dielectric breakdown material has a glass transition temperature that is lower than a sintering temperature of the high-permittivity ceramic powder particles.

7. The article of manufacture of claim 1, wherein the first layer has a thickness of about 100 Angstroms.

8. The article of manufacture of claim 2, wherein the second layer has a thickness of about 100 Angstroms.

9. The article of manufacture of claim 1, wherein the coated high permittivity ceramic powder particles have a volume of about 1.0 μ

m³.

10. The article of manufacture of claim 2, wherein the second layer comprises 6.0% of the volume of the coated high permittivity ceramic powder particles.

11. The article of manufacture of claim 1, wherein the relative permittivity of the coated high permittivity ceramic powder particles is about 29,480.

12. The article of manufacture of claim 1, wherein the dielectric layer has a voltage breakdown greater than 1.0×

10⁶ V/cm.

13. The article of manufacture of claim 12, wherein the voltage breakdown is in a range of 1.0×

10⁶ V/cm to 5.0×

10⁶ V/cm.

14. The article of manufacture of claim 1, wherein the dielectric layer has a thickness of about 12.7×

10<sup>−

6</sup> m.

15. A capacitor comprising:

first and second electrodes; and

a dielectric layer located between the first and second electrodes, the dielectric layer including high-permittivity ceramic powder particles coated with a first layer of high dielectric breakdown material and isostatically pressed together, wherein the first layer of high dielectric breakdown material comprises material different from the high-permittivity ceramic powder particles, wherein the high-permittivity ceramic powder particles comprise composition-modified barium titanate, wherein the first layer of high dielectric breakdown material comprises alumina.

16. The capacitor of claim 15, wherein at least one of the first and second electrodes includes a nickel electrode.

17. The capacitor of claim 15, further comprising a second coating layer comprising a second high dielectric breakdown material.

18. The capacitor of claim 17, wherein the second high dielectric breakdown material comprises a glass.

19. The capacitor of claim 17, wherein the second high dielectric breakdown material comprises calcium magnesium aluminosilicate glass.

20. The capacitor of claim 15, wherein the dielectric layer has a layer has a voltage breakdown greater than 1×

10⁶ V/cm.

21. The capacitor of claim 17, wherein the second high dielectric breakdown material has a glass transition temperature that is lower than a sintering temperature of the high-permittivity ceramic particles.

22. The article of manufacture of claim 15, wherein the dielectric layer has a thickness of about 12.7×

10<sup>−

6</sup> m.