Energy storage structures and fabrication methods thereof

• US 9,831,533 B2
• Filed: 03/17/2014
• Issued: 11/28/2017
• Est. Priority Date: 03/15/2013
• Status: Expired due to Fees

• Current Assignee: The Paper Battery Company, Inc.
• Original Assignee: The Paper Battery Company, Inc.
• Inventors: Rich, Dave, KULKARNI, Sudhir Rajaram, Friello, Renato, Sudano, Anthony, MEHTA, Shreefal Sudhir
• Primary Examiner(s): Smith, Nicholas A
• Application Number:
  US14/215,571
• Publication Number:
  US 20140287277A1
• Time in Patent Office: 1,352 Days
• CPC Class Codes: H01G 11/08 Structural combinations, e.g. assembly or connection, of hybrid or EDL capacitors with other electric components, at least one hybrid or EDL capacitor being the main component
• CPC Class Codes: H01G 11/12 Stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/52 Separators
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/80 Gaskets; Sealings
• CPC Class Codes: H01G 11/84 Processes for the manufacture of hybrid or EDL capacitors, or components thereof
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/045 Cells or batteries with folded plate-like electrodes
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 10/4264 with capacitors
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/55 on the same side of the cell
• CPC Class Codes: H01M 50/557 Plate-shaped terminals
• CPC Class Codes: H01M 50/564 characterised by their manufacturing process
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• 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: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding

Abstract

Energy storage structures and fabrication methods are provided. The method include: providing first and second conductive sheet portions separated by a permeable separator sheet, and defining, at least in part, outer walls of the energy storage structure, the first and second surface regions of the first and second conductive sheet portions including first and second electrodes facing first and second (opposite) surfaces of the permeable separator sheet; forming an electrolyte receiving chamber, defined, at least in part, by the first and second surface regions, including: bonding the first and second conductive sheet portions, and the permeable separator sheet together with at least one bonding border forming a bordering frame around at least a portion of the first and second electrodes; and providing an electrolyte within the electrolyte receiving chamber, including in contact with the first and second electrodes, with the electrolyte being capable of passing through the permeable separator sheet.

Claims

1. A method comprising:

fabricating a pouchless supercapacitor structure, the fabricating comprising;

providing a first conductive sheet portion and a second conductive sheet portion separated by a permeable separator sheet, the first conductive sheet portion and the second conductive sheet portion each defining, at least in part, a respective outer wall of the supercapacitor structure;

providing a first electrode at a first surface region of the first conductive sheet portion, the first electrode facing a first surface of the permeable separator sheet and providing a second electrode at a second surface region of the second conductive sheet portion, the second electrode facing a second surface of the permeable separator sheet, the first surface and the second surface of the permeable separator sheet being opposite surfaces thereof;

providing at least one border between the first conductive sheet portion and the second conductive sheet portion, the at least one border encircling and forming a bordering frame around at least one of the first electrode or the second electrode, wherein the bordering frame facilitates forming an electrolyte receiving chamber extending through the permeable separator sheet, the electrolyte receiving chamber being defined, at least in part, by the first conductive sheet portion, the second conductive sheet portion and the at least one border; and

providing an electrolyte within the electrolyte receiving chamber, including in contact with the first electrode and the second electrode, wherein the electrolyte is capable of passing through the permeable separator sheet, and wherein the electrolyte is provided through a port insert through a border of the at least one border of the pouchless supercapacitor structure.

2. The method of claim 1, wherein the first conductive sheet portion and the second conductive sheet portion are current collectors of the supercapacitor structure, and providing the first electrode and the second electrode comprises coating the first surface region of the first conductive sheet portion and the second surface region at the second conductive sheet portion with a common electrode material to form the first electrode and the second electrode.

3. The method of claim 1, wherein the bordering frame provides a fluid-tight seal around the electrolyte receiving chamber and comprises a chemically resistant material, the chemically resistant material inhibiting leakage from the electrolyte receiving chamber.

4. The method of claim 1, wherein providing the at least one border comprises using a flowable material in forming the at least one border.

5. The method of claim 1, wherein the at least one border comprises a pressure sensitive adhesive.

6. The method of claim 1, further comprising providing at least one conductive tab electrically connected to and extending outward from at least one of the first conductive sheet portion or the second conductive sheet portion.

7. The method of claim 1, wherein the bordering frame comprises an electrical insulator, the electrical insulator facilitating electrically isolating the first conductive sheet portion from the second conductive sheet portion.

8. The method of claim 1, wherein providing the at least one border further comprises heating the at least one bonding border to bond the first conductive sheet portion, the second conductive sheet portion, and the permeable separator sheet together.

9. The method of claim 1, wherein providing the at least one border further comprises applying pressure to the at least one border to bond the first conductive sheet portion, the second conductive sheet portion, and the permeable separator sheet together.

10. The method of claim 1, further comprising:

providing a multi-cell supercapacitor structure, wherein outer surfaces of the multi-cell supercapacitor structure are defined by at least one conductive sheet defining current collectors of different cells of the multi-cell supercapacitor structure, wherein cells of the multi-cell supercapacitor structure each include a respective permeable separator sheet within an electrolyte receiving chamber, and the cells being ionically isolated from each other.

11. The method of claim 10, wherein the providing comprises folding the at least one conductive sheet to define the one or more outer surfaces of the multi-cell supercapacitor structure.

12. The method of claim 10, wherein the fabricating comprises fabricating the multi-cell supercapacitor structure as a flexible energy storage structure, the flexible energy storage structure being capable of being bent at any angle.

13. The method of claim 10, further comprising providing at least one conductive tab electrically connected to and extending outward from the at least one conductive sheet.

19. The method of claim 1, wherein the at least one border is disposed, at least in part, between the permeable separator sheet and at least one of the first conductive sheet portion or the second conductive sheet portion.

20. The method of claim 19, wherein the at least one border traps and seals the permeable separator sheet at the edge thereof to, in part, form the electrolyte receiving chamber.

14. A structure comprising:

a pouchless supercapacitor structure, the supercapacitor structure comprising;

a first conductive sheet portion and a second conductive sheet portion separated by a permeable separator sheet, the first conductive sheet portion and the second conductive sheet portion each defining, at least in part, a respective outer wall of the supercapacitor structure;

providing a first electrode at a first surface region of the first conductive sheet portion, the first electrode facing a first surface of the permeable separator sheet and providing a second electrode at a second surface region of the second conductive sheet portion, the second electrode facing a second surface of the permeable separator sheet, the first surface and the second surface of the permeable separator sheet being opposite surfaces thereof;

providing at least one border between the first conductive sheet portion and the second conductive sheet portion, the at least one border encircling and forming a bordering frame around at least one of the first electrode or the second electrode, wherein the bordering frame facilitates defining an electrolyte receiving chamber extending through the permeable separator sheet, the electrolyte receiving chamber being defined, at least in part, by the first conductive sheet portion, the second conductive sheet portion and the at least one border; and

an electrolyte within the electrolyte receiving chamber, including in contact with the first electrode and the second electrode, wherein the electrolyte is capable of passing through the permeable separator sheet, and wherein the electrolyte is provided through a port insert through a border of the at least one boarder of the pouchless supercapacitor structure.

15. The structure of claim 14, further comprising:

multiple supercapacitor structures, the multiple supercapacitor structures comprising multiple first conductive sheet portions of a common conductive sheet separated from multiple second conductive sheet portions of the common conductive sheet by a common line of symmetry, wherein the common conductive sheet is folded along the common line of symmetry to substantially align the multiple first conductive sheet portions and the multiple second conductive sheet portions substantially with the permeable separator sheet therebetween.

16. The structure of claim 14, further comprising at least one conductive tab electrically connected to and extending outward from at least one of the first conductive sheet portion or the second conductive sheet portion.

17. The structure of claim 14, wherein providing the first electrode and the second electrode comprises coating, at least in part, the first surface region of the conductive sheet portion and the second surface region of the second conductive sheet portion with a common electrode material to form the first electrode and the second electrode.

18. The structure of claim 14, further comprising:

a battery structure, the battery structure comprising a set of first conductive tabs;

wherein the supercapacitor structure comprises a set of second conductive tabs; and

an insulating pouch, the insulating pouch surrounding the battery structure and the supercapacitor, wherein the set of first conductive tabs and the set of second conductive tabs are electrically connected.

21. The structure of claim 14, wherein the at least one border is disposed, at least in part, between the permeable separator sheet and at least one of the first conductive sheet portion or the second conductive sheet portion.

22. The structure of claim 21, wherein the at least one border traps and seals the permeable separator sheet at the edge thereof to, in part, form the electrolyte receiving chamber.