Method for fabricating a supercapacitor electronic battery

• US 8,863,363 B2
• Filed: 08/03/2010
• Issued: 10/21/2014
• Est. Priority Date: 08/07/2009
• Status: Expired due to Fees

• Current Assignee: Oerlikon Advanced Technologies AG, Werner Oskar Martienssen By Rosalinda Martienssen
• Original Assignee: Oerlikon Advanced Technologies AG
• Inventors: Martienssen, Werner Oskar, Reynolds, Glyn Jeremy
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US13/389,368
• Publication Number:
  US 20120216379A1
• Time in Patent Office: 1,540 Days
• Field of Search: 29/254.2, 295/921, 361/301.1, 361/311, 361/500, 361/502, 361/523
• US Class Current: 29/25.42
• CPC Class Codes: H01G 11/00 Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
• CPC Class Codes: H01G 11/04 Hybrid capacitors
• CPC Class Codes: H01G 11/22 Electrodes
• CPC Class Codes: H01G 11/24 characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor
• CPC Class Codes: H01G 11/56 Solid electrolytes, e.g. gels; Additives therein
• CPC Class Codes: H01G 11/70 characterised by their structure
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/84 Processes for the manufacture of hybrid or EDL capacitors, or components thereof
• CPC Class Codes: H01G 9/0029 Processes of manufacture
• CPC Class Codes: H01G 9/15 Solid electrolytic capacitors H01G11/00 takes precedence
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/43 Electric condenser making
• CPC Class Codes: Y10T 29/435 Solid dielectric type
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49112 including laminating of indefinite length material

Abstract

A method for fabricating a supercapacitor-like electronic battery includes forming a first current collectors on a substrate. A first electrode is formed on the first current collector. A first electrode is formed from a first solid state electrolyte and a first conductive material where the first conductive material is irreversible to the mobile ions contained in the first solid state electrolyte and the first conductive material exceeds the percolation limit. An electrolyte is formed on the first electrode. A second electrode is formed on the electrolyte. The second electrode is formed from a second solid state electrolyte and a second conductive material where the second conductive material is irreversible to the mobile ions contained in the second solid state electrolyte and the second conductive material exceeds the percolation limit. A second current collector is formed on the second electrode.

Claims

1. A method for fabricating a supercapacitor electronic battery comprising:

providing a substrate;

forming a first current collector on said substrate;

forming a first electrode on said first current collector, said first electrode being formed from a first solid state electrolyte and a first conductive material, said first conductive material being irreversible to mobile ions contained in said first solid state electrolyte, said first conductive material exceeding the percolation limit;

forming an electrolyte on said first electrode;

forming a second electrode on said electrolyte, said second electrode being formed from a second solid state electrolyte and a second conductive material, said second conductive material being irreversible to mobile ions contained in said second solid state electrolyte, said second conductive material exceeding the percolation limit; and

forming a second current collector on said second electrode.

2. The method according to claim 1, further comprising forming an encapsulation layer over said second current collector, said second electrode, said electrolyte, said first electrode and said first current collector.

3. The method according to claim 2, wherein said encapsulation layer further comprising an organic polymer.

4. The method according to claim 2, wherein said encapsulation layer further comprising an inorganic material.

5. The method according to claim 2, further comprising applying a metal overlayer to said encapsulation layer.

6. The method according to claim 2, wherein said encapsulation layer further comprising one or multiple applications of various encapsulation materials.

7. The method according to claim 1, wherein said first current collector further comprising at least two layers consisting of different materials.

8. The method according to claim 1, wherein said second current collector further comprising at least two layers consisting of different materials.

9. The method according to claim 1, wherein said first solid state electrolyte having a ratio to said first conductive material so that an electrochemical double layer forms around surface atoms of each nanoscopic grain of conductor.

10. The method according to claim 1, wherein said first solid state electrolyte and said first conductive material are intimately mixed at the nanoscale to ensure that the maximum number of conductive atoms or molecules are adjacent to solid electrolyte molecules.

11. The method according to claim 1, wherein said electrolyte further comprising a single insulating component.

12. The method according to claim 1, wherein said electrolyte further comprising a multicomponent nano structure.

13. The method according to claim 1, wherein said electrolyte further comprising a nanocomposite.

14. The method according to claim 13, wherein said nanocomposite further comprising:

a ferroelectric material; and

an electrolyte material.

15. The method according to claim 14, wherein said ferroelectric material further comprising a relaxor ferroelectric material.

16. The method according to claim 1, wherein said electrolyte having a thickness in the range 100 Angstroms to 2 microns.

17. The method according to claim 1, wherein said electrolyte further comprising codepositing concurrently a multiphase material.

18. The method according to claim 1, wherein said first electrode further comprising co-depositing concurrently a multiphase material.

19. The method according to claim 18, wherein said second electrode further comprising co-depositing concurrently a multiphase material.