JP4248682B2 - Electric double layer capacitor - Google Patents

Electric double layer capacitor Download PDF

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Publication number
JP4248682B2
JP4248682B2 JP16319799A JP16319799A JP4248682B2 JP 4248682 B2 JP4248682 B2 JP 4248682B2 JP 16319799 A JP16319799 A JP 16319799A JP 16319799 A JP16319799 A JP 16319799A JP 4248682 B2 JP4248682 B2 JP 4248682B2
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activated carbon
metal foil
separator
bent
carbon sheet
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JP2000353643A (en
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重明 長竹
利行 久保
令朗 伊藤
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—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
    • H01G11/10—Multiple hybrid or EDL capacitors, e.g. arrays or modules
    • H01G11/12—Stacked hybrid or EDL capacitors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—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
    • H01G11/22—Electrodes
    • H01G11/24—Electrodes 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—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
    • H01G11/74—Terminals, e.g. extensions of current collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
    • H01G9/004—Details
    • H01G9/02—Diaphragms; Separators
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/13—Energy storage using capacitors

Description

【０００１】
【発明の属する技術の分野】
本発明は、電気二重層コンデンサに関し、特に電気二重層コンデンサの電極体の製造方法に関する。
【０００２】
【従来の技術】
電気二重層コンデンサの電極体を形成する方法として、図６（ａ）に示したように、アルミ箔５０、活性炭クロス５１、セパレータ５２、活性炭クロス５３、アルミ箔５４を順に重ねて圧接することにより、５層構造の電極体５５を形成する方法が知られている。このようにして形成された電極体５５においては、セパレータ５２に電解質溶液が含浸され、該電解質溶液と活性炭クロス５１，５３が接する界面に電気二重層が構成される。そして、アルミ箔５０，５４を介して、該電気二重層への電荷の充電と、該電気二重層充電された電荷の放電が行われる。
【０００３】
電極体５５によって電気二重層コンデンサを構成する場合、多数の電極体５５を積層して並列に接続することにより充電容量を高めることができる。しかし、図６（ａ）に示したように、アルミ箔５０，５４、活性炭クロス５１，５３、及びセパレータ５２として、それぞれ短冊状に切断されたものを用いた場合は、電極体５５の積層に要する工数が極めて多くなってしまう。
【０００４】
そこで、図６（ｂ）に示したように、長尺のセパレータ６０を使用して、該セパレータ６０を所定長ごとに異なる方向に交互に折り返し、蛇腹状にされたセパレータ６０の間にアルミ箔６１を挟んだ活性炭クロス６２を配置するという操作を繰り返すことにより、上述した５層の電極体６３を積層していく製造方法が提案されている（特開平１０−１２５５５９号公報）。
【０００５】
この製造方法によれば、電極体６３の積層に要する工数を低減することができる。しかし、この製造方法においては、予め活性炭クロス６２によりアルミ箔６１を挟んだ活性炭クロス６２を形成しておく必要があり、また、積層が終了した後に、アルミ箔同士の導通をとって正負の充放電電極を形成する必要があった。そのため、電極体の積層に要する全体的な製造工数を更に低減することが要望されていた。
【０００６】
【発明が解決しようとする課題】
本発明は上記背景を鑑みてなされたものであり、電極体の形成及び積層に要する製造工数を低減することができる電気二重層コンデンサの電極製造方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記目的を達成するため、本発明の第１の実施の態様は、電解質溶液が含浸され、予め所定長ごとに異なる方向に交互に折り返された長尺のセパレータの一方の面に、予め該セパレータの折り曲げ形状に合わせて折り曲げられた長尺の第１の活性炭シートを重ねる工程と、前記第１の活性炭シートに、予め前記第１の活性炭シートの折り曲げ形状に合わせて折り曲げられた長尺の第１の金属箔を重ねる工程と、前記セパレータの他方の面に、予め前記セパレータの折り曲げ形状に合わせて折り曲げられた長尺の第２の活性炭シートを重ねる工程と、前記第２の活性炭シートに、予め前記第２の活性炭シートの折り曲げ形状に合わせて折り曲げられた長尺の第２の金属箔を重ねる工程と、前記各工程により重ねられた前記セパレータと前記第１の活性炭シートと前記第１の金属箔と前記第２の活性炭シートと前記第２の金属箔を、さらに折り曲げて圧接することにより、前記第１の金属箔と前記第１の活性炭シートと前記セパレータと前記第２の活性炭シートと前記第２の金属箔とからなる５層の電極体を連続して構成する工程とを含むことを特徴とする。
【０００８】
かかる本発明によれば、詳細は後述するが、前記セパレータの交互に折り返された各部分と、該各部分に重ねられた、前記第１の活性炭シート、前記第2の活性炭シート、前記第１の金属箔、及び前記第２の活性炭シートの各部分とにより、前記５層の電極体が複数個連続して形成され、該複数個の電極体が積層される。そして、各電極体は前記第１の金属箔と前記第２の金属箔とによって互いに導通されるため、各電極体間の導通を取る工程は不要となる。そのため、電極体の積層に要する製造工数を大幅に低減させることができる。
【０００９】
また、前記第１の活性炭シートの前記第１の金属箔と接する面に、前記セパレータの折り返し部分に応じて折り返される部分を除いて、金属を溶射する工程を、さらに含むことを特徴とする。
【００１０】
前記第１活性炭シートの前記第１金属箔と接する面に予め金属を溶射しておくことで、前記第１活性炭シートと前記第１金属箔との接触抵抗を低下させることができる。しかし、本願発明者らは、前記第１の活性炭シートの前記第１の金属箔と接する面の全面に金属が溶射されている場合は、前記第１の活性炭シートを折り曲げたときに、溶射されていた金属が針状に割れて前記セパレータを突き破り、前記第１活性炭シートと前記第２活性炭シートとを導通させてしまう（導通不良）場合があることを知見した。そこで、本発明により、前記第１の活性炭シートの前記第１の金属箔と接する面の折り曲げ部以外に金属を溶射することで、このような導通不良が生じることを防止することができる。また、折り曲げ部に金属が溶射されていないので前記第１活性炭シートの折り曲げが容易になる。
また、前記第１の金属箔の山側の折り曲げ部に、前記第１の活性炭シートの山側の折り曲げ部に合わせた婉曲形状を持たせる工程を、さらに含むことを特徴とする。
かかる本発明によれば、前記第１の金属箔と前記第１の活性炭シート間に隙間が生じることを防止して、電極体の容量が減少することを防ぐことができる。
【００１１】
また、本発明の第２の実施の態様は、電解質溶液が含浸され、予め所定長ごとに異なる方向に交互に折り返された長尺のセパレータの両面に、予め該セパレータの折り曲げ形状に合わせて折り曲げられた長尺の金属箔であって、該セパレータと接する面に、該セパレータの折り返し部分に応じて折り返される部分を除いて活性炭層を形成する表面処理が施された第１及び第２の金属箔を重ねる工程と、前記工程により重ねられた前記セパレータと前記第１の金属箔と前記第２の金属箔とを、さらに折り曲げて圧接することにより、前記第１の金属箔と前記第１の金属箔に形成された活性炭層と前記セパレータと前記第２の金属箔に形成された活性炭層と前記第２の金属箔とからなる５層の電極体を連続して構成する工程とを含むことを特徴とする。
【００１２】
かかる本発明によれば、前記第１の金属箔と前記第２の金属箔の折り返し部分には活性炭層が形成されないため、前記第１の金属箔と前記第２の金属箔を容易に折り曲げることができる。また、前記第１の金属箔と該第１の金属箔に形成される活性炭層との位置、及び前記第２の金属箔と該第２の金属箔に形成される活性炭層との位置が前記圧接を行う前に予め固定されるため、前記圧接を行ったときに、前記セパレータと前記第１の金属箔と前記第２の金属箔との位置がずれることがない。そのため、このような位置ずれにより、形成された５層の電極体の容量が減少することを防止することができる。
【００１３】
【発明の実施の形態】
本発明の実施の形態について、図１〜図５を参照して説明する。図１は５層構造の電極体の製造方法の説明図、図２は図１の製造方法により製造した電極体の構造説明図、図３は活性炭クロスへの金属溶射の説明図、図４はアルミ箔の折り曲げ形状の説明図、図５はアルミ箔に活性炭クロスを貼着した場合の５層構造の電極体の製造方法の説明図である。
【００１４】
先ず、図１〜図４を参照して、本発明の第１の実施の形態について説明する。図１を参照して、本実施の形態では、それぞれ長尺の、厚さ０．１ｍｍ程度の第１のアルミ箔１（本発明の第１の金属箔に相当する）及び第２のアルミ箔２（本発明の第２の金属箔に相当する）と、繊維状の活性炭を布状とした第１の活性炭クロス３（本発明の第１の活性炭シートに相当する）及び第２の活性炭クロス４（本発明の第２の活性炭シートに相当する）と、ポリエチレンやポリプロプレン等の樹脂材により形成した濾過膜を用いて構成したセパレータ５とを材料として、第１のアルミ箔１−第１の活性炭クロス３−セパレータ５−第２の活性炭クロス４−第２のアルミ箔２という５層構造からなる電極体を形成する。
【００１５】
そして、各材料は予め所定長毎に異なる方向に交互に折り返されて蛇腹形状とされる。具体的には、５層構造の中心となるセパレータ５の折り曲げ形状に合わせて、セパレータ５と接して重ねられる第１の活性炭クロス３と第２の活性炭クロス４とが折り曲げられる。また、第１の活性炭クロス３の折り曲げ形状に合わせて第１の活性炭クロス３に接して重ねられる第１のアルミ箔１が折り曲げられ、第２の活性炭クロス４の折り曲げ形状に合わせて該第２の活性炭クロス４と接して重ねられる第２のアルミ箔２が折り曲げられる。
【００１６】
このように予め蛇腹状に折り曲げられた各材料を重ねて、圧接することにより、図２に示すように、第１のアルミ箔１−第１の活性炭クロス３−セパレータ５−第２の活性炭クロス４−第２のアルミ箔２という５層構造の電極体２０が複数個連続して形成される。
【００１７】
このようにして形成された各電極体２０は、第１のアルミ箔１（正極）と第２のアルミ箔２（負極）とにより正極同士及び負極同士が互いに導通される。そのため、各電極体２０間の導通をとる処理は不要であり、少ない工数で電極体２０を形成、積層することができる。また、各材料を予め蛇腹形状とすることで、各材料を重ねるときのハンドリンングを容易にすることができる。
【００１８】
尚、第１の活性炭クロス３と第１のアルミ箔１との間の接触抵抗を低減させるために、第１の活性炭シート３の第１のアルミ箔１と接する側にアルミ溶射を施すことが効果的である（第２の活性炭クロス４と第２のアルミ箔２についても同様）。しかし、第１の活性炭クロス３の全面にアルミ溶射を行うと、図１及び図２に示したように圧接したときに、折り曲げられた部分に溶射されていたアルミが針状に剥がれ、針状のアルミが第１の活性炭クロス３とセパレータ５を突き破って第２の活性炭クロス４に達する場合ある。そして、この場合には、第１の活性炭クロス３と第２の活性炭クロス４が導通する不良となる。
【００１９】
そこで、図３を参照して、第１の活性炭クロス３の折り曲げ部Ａを除いた部分Ｂにのみアルミ溶射を行うようにすることで、第１の活性炭クロス３を折り曲げたときに、上述したように針状のアルミが発生して不良が生じることを防止することができる。さらに、このように折り曲げ部Ａにアルミ溶射を行わないことにより、第１活性炭クロス３の折り曲げを容易にすることができる。
【００２０】
また、図４（ａ）を参照して、第１のアルミ箔１と第１の活性炭クロス３を普通に折り曲げると、薄い（０．１ｍｍ程度）第１のアルミ箔１は鋭角に折り曲がるが、厚みがある第１の活性炭クロス３は鋭角には折り曲がらない。そのため、両者を重ねると、第１のアルミ箔１の山側の折り曲げ部Ｃと第１の活性炭クロス３の山側の折り曲げ部Ｄとが干渉して、第１のアルミ箔１の谷側の折り曲げ部Ｅと第１の活性炭クロス３の谷側の折り曲げ部Ｆとの間に隙間δが生じる場合がある。そして、この場合には、隙間δの部分には上述した５層構造が形成されないため、電極体の容量が減少してしまう。
【００２１】
そこで、図４（ｂ）に示したように、第１のアルミ箔１の山側の折り曲げ部Ｃに、第１の活性炭クロス３の山側の折り曲げ部Ｄに合わせた婉曲形状を持たせることにより、図４（ａ）に示したような隙間δが生じることを防止し、電極体の容量が減少することを防ぐことができる。
【００２２】
尚、本実施の形態では、本発明の活性炭シートとして、繊維状の活性炭を布状とした活性炭クロスを用いたが、粉末状、粒状、繊維状の活性炭を、ポリテトラフルオロエチレン（ＰＴＦＥ）、セルロース等のバインダーと共に混合し、シート状にしたものを用いてもよい。
【００２３】
次に、図５を参照して、本発明の第２の実施の形態について説明する。本実施の形態においては、図５（ａ）に示したように、片面に活性炭クロス片４１が貼着された（本発明の活性炭層を形成する表面処理に相当する）厚さ０．１ｍｍ程度のアルミ箔４０を用いて５層の電極体を形成する。
【００２４】
そして、図５（ｂ）を参照して、アルミ箔４０を、上述した第１の実施の形態と同様に蛇腹状に折り曲げられたセパレータ４４の形状に合わせて、活性炭クロス４１が貼着された側を内側にして折り曲げた第１のアルミ箔４２（本発明の第１の金属箔に相当する）と、活性炭クロス４１が貼着された面を外側にして折り曲げられた第２のアルミ箔４３（本発明の第２の金属箔に相当する）とを、セパレータ４４の両面に重ねて圧接する。
【００２５】
ここで、図５（ａ）を参照して、活性炭クロス片４１は、アルミ箔４０（第１のアルミ箔４２及び第２のアルミ箔４３）の折り曲げ部Ｇを除いて貼着される。そのため、第１のアルミ箔４２と第２のアルミ箔の折り曲げは、薄いアルミ箔４０の部分のみに対して行えばよく、容易に折り曲げを行うことができる。
【００２６】
そして、図５（ａ）を参照して、アルミ箔４０と活性炭クロス４１が位置が予め固定されるので、図５（ｂ）に示したように第１のアルミ箔４２とセパレータ４４と第２のアルミ箔４３とを重ねて圧接したときに、第１のアルミ箔４２と第２のアルミ箔４３のアルミ箔部分と活性炭クロス部分との位置ずれが生じることがない。
【００２７】
そのため、第１のアルミ箔４２のアルミ箔部分−第１のアルミ箔に貼着された活性炭クロス−セパレータ４４−第２のアルミ箔に貼着された活性炭クロス−第２のアルミ箔のアルミ箔部分、という５層構造の電極体を位置ずれによる充電容量の減少を防いで形成、積層することができる。
【００２８】
尚、本実施の形態では、図５（ａ）を参照して、アルミ箔４０に活性炭クロス片４１を貼着することにより、アルミ箔４０の表面に活性炭層を形成したが、アルミ箔４０に活性炭を主成分とする塗工剤を、折り曲げ部Ｇを除いて（マスクして）塗工することにより、アルミ箔４０の表面に活性炭層を形成するようにしてもよい。
【図面の簡単な説明】
【図１】５層の電極体の製造方法の説明図。
【図２】図１の製造方法により形成した電極体の構造説明図。
【図３】活性炭クロスへの金属溶射の説明図。
【図４】アルミ箔の折り曲げ形状の説明図。
【図５】５層の電極体の製造方法の説明図。
【図６】従来の電極製造方法の説明図。
【符号の説明】
１…第１のアルミ箔、２…第２のアルミ箔、３…第１の活性炭クロス、４…第２の活性炭クロス、５…セパレータ、２０…電極体、４０…アルミ箔、４１…活性炭クロス片[0001]
[Field of the Invention]
The present invention relates to an electric double layer capacitor, and more particularly to a method for manufacturing an electrode body of an electric double layer capacitor.
[0002]
[Prior art]
As a method of forming an electrode body of an electric double layer capacitor, as shown in FIG. 6A, an aluminum foil 50, an activated carbon cloth 51, a separator 52, an activated carbon cloth 53, and an aluminum foil 54 are sequentially stacked and pressed. A method for forming an electrode body 55 having a five-layer structure is known. In the electrode body 55 formed as described above, the separator 52 is impregnated with the electrolyte solution, and an electric double layer is formed at the interface between the electrolyte solution and the activated carbon cloths 51 and 53. Then, charging of the electric double layer and discharging of the electric charge charged in the electric double layer are performed via the aluminum foils 50 and 54.
[0003]
When an electric double layer capacitor is constituted by the electrode body 55, the charge capacity can be increased by stacking a large number of electrode bodies 55 and connecting them in parallel. However, as shown in FIG. 6A, when the aluminum foils 50 and 54, the activated carbon cloths 51 and 53, and the separators 52 that are cut into strips are used, the electrode bodies 55 are stacked. The man-hour required will become very large.
[0004]
Therefore, as shown in FIG. 6B, a long separator 60 is used, and the separator 60 is alternately folded back in different directions for each predetermined length, and an aluminum foil is interposed between the bellows-like separator 60. A manufacturing method has been proposed in which the above-described five-layered electrode body 63 is laminated by repeating the operation of disposing the activated carbon cloth 62 with 61 interposed therebetween (Japanese Patent Laid-Open No. 10-125559).
[0005]
According to this manufacturing method, the number of man-hours required for stacking the electrode bodies 63 can be reduced. However, in this manufacturing method, it is necessary to form the activated carbon cloth 62 in which the aluminum foil 61 is sandwiched between the activated carbon cloths 62 in advance, and after the lamination is completed, the aluminum foils are electrically connected to each other to make positive and negative charges. It was necessary to form a discharge electrode. For this reason, it has been desired to further reduce the overall number of manufacturing steps required for stacking the electrode bodies.
[0006]
[Problems to be solved by the invention]
The present invention has been made in view of the above background, and an object of the present invention is to provide an electrode manufacturing method for an electric double layer capacitor that can reduce the number of manufacturing steps required for forming and laminating electrode bodies.
[0007]
[Means for Solving the Problems]
To achieve the above object, an aspect of the first embodiment of the present invention, the electrolyte solution was impregnated on one surface of the separator elongated folded alternately in a different direction for each advance predetermined length, advance the separator of the bent Ru together first activated carbon long sheet folded according to the shape process, the first activated carbon sheet, elongate folded to fit in advance on the bent shape of the first activated carbon sheet a step of Ru superimposed first metal foil, and the surface of the other side of the pre-Symbol separator, Ru superimposed second activated carbon sheet of elongated bent to fit the bent shape of the previously said separator step, the second of the activated carbon sheet, in advance and the second Ru superimposed second metal foil elongated bent to fit the bent shape of the activated carbon sheet process, the first and the separator superposed by the steps Activated carbon sheet and wherein the first metal foil and the second activated carbon sheet second metal foil by pressure contact further bending, and the first metal foil and the first activated carbon sheet and the separator And a step of continuously forming a five-layered electrode body composed of the second activated carbon sheet and the second metal foil.
[0008]
According to the present invention, as will be described in detail later, the portions of the separator that are alternately folded, and the first activated carbon sheet, the second activated carbon sheet, A plurality of the five-layer electrode bodies are continuously formed by the metal foil and each portion of the second activated carbon sheet, and the plurality of electrode bodies are laminated. And since each electrode body is mutually connected by said 1st metal foil and said 2nd metal foil, the process of taking conduction between each electrode body becomes unnecessary. Therefore, the number of manufacturing steps required for stacking the electrode bodies can be greatly reduced.
[0009]
Further, the method further includes a step of thermally spraying a metal on a surface of the first activated carbon sheet that is in contact with the first metal foil except a portion that is folded according to a folded portion of the separator.
[0010]
By previously thermally spraying a metal on the surface of the first activated carbon sheet that contacts the first metal foil, the contact resistance between the first activated carbon sheet and the first metal foil can be reduced. However, when the metal is sprayed on the entire surface of the first activated carbon sheet contacting the first metal foil, the inventors of the first activated carbon sheet are sprayed when the first activated carbon sheet is folded. It has been found that the metal that has been cracked in a needle shape, breaks through the separator, and may cause the first activated carbon sheet and the second activated carbon sheet to conduct (conductivity failure). Therefore, according to the present invention, it is possible to prevent such a conduction failure from occurring by spraying the metal other than the bent portion of the surface in contact with the first metal foil of the first activated carbon sheet. Further, since the metal is not sprayed on the bent portion, the first activated carbon sheet can be bent easily.
In addition, the method further includes the step of providing the bent portion on the mountain side of the first metal foil with a bent shape that matches the bent portion on the mountain side of the first activated carbon sheet.
According to this invention, it can prevent that a clearance gap produces between said 1st metal foil and said 1st activated carbon sheet, and can prevent that the capacity | capacitance of an electrode body reduces.
[0011]
Also, aspects of the second embodiment of the present invention, the electrolyte solution is impregnated, on both surfaces of the separator in advance elongated folded alternately in a different direction for each predetermined length, folded in accordance with the bent shape of the advance the separator 1st and 2nd metal in which the surface treatment which forms the activated carbon layer except for the part folded back according to the folding | turning part of this separator on the surface which contacted this separator was carried out long metal foil a step of Ru superimposed foil, said step and the separator superposed by the first metal foil and the second metal foil by pressure contact further bending, the first metal foil and the first And continuously forming a five-layer electrode body comprising the activated carbon layer formed on the metal foil, the separator, the activated carbon layer formed on the second metal foil, and the second metal foil. With features That.
[0012]
According to the present invention, since the activated carbon layer is not formed at the folded portion of the first metal foil and the second metal foil, the first metal foil and the second metal foil can be easily folded. Can do. Further, the position of the first metal foil and the activated carbon layer formed on the first metal foil, and the position of the second metal foil and the activated carbon layer formed on the second metal foil are Since it is fixed in advance before performing the pressure contact, the positions of the separator, the first metal foil, and the second metal foil do not shift when the pressure contact is performed. Therefore, it is possible to prevent the capacitance of the formed five-layer electrode body from being reduced due to such misalignment.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described with reference to FIGS. 1 is an explanatory view of a manufacturing method of an electrode body having a five-layer structure, FIG. 2 is an explanatory view of a structure of an electrode body manufactured by the manufacturing method of FIG. 1, FIG. 3 is an explanatory view of metal spraying on activated carbon cloth, and FIG. FIG. 5 is an explanatory view of a bent shape of an aluminum foil, and FIG. 5 is an explanatory view of a manufacturing method of an electrode body having a five-layer structure when activated carbon cloth is stuck to the aluminum foil.
[0014]
First, a first embodiment of the present invention will be described with reference to FIGS. Referring to FIG. 1, in the present embodiment, a long first aluminum foil 1 (corresponding to the first metal foil of the present invention) and a second aluminum foil, each having a thickness of about 0.1 mm. 2 (corresponding to the second metal foil of the present invention), a first activated carbon cloth 3 (corresponding to the first activated carbon sheet of the present invention) and a second activated carbon cloth having a fibrous activated carbon cloth. 4 (corresponding to the second activated carbon sheet of the present invention) and a separator 5 constituted by using a filtration membrane formed of a resin material such as polyethylene or polypropylene, the first aluminum foil 1-the first An electrode body having a five-layer structure of activated carbon cloth 3 -separator 5 -second activated carbon cloth 4 -second aluminum foil 2 is formed.
[0015]
Each material is a bellows is returned Ri folded alternately advance in a different direction to a predetermined length each. Specifically, the first activated carbon cloth 3 and the second activated carbon cloth 4 that are stacked in contact with the separator 5 are bent in accordance with the bent shape of the separator 5 that is the center of the five-layer structure. In addition, the first aluminum foil 1 stacked in contact with the first activated carbon cloth 3 is folded according to the bent shape of the first activated carbon cloth 3, and the second aluminum foil 1 is bent according to the folded shape of the second activated carbon cloth 4. The second aluminum foil 2 stacked in contact with the activated carbon cloth 4 is bent.
[0016]
As shown in FIG. 2, the respective materials bent in advance in a bellows shape are stacked and press-contacted to form a first aluminum foil 1-a first activated carbon cloth 3-a separator 5-a second activated carbon cloth. 4-A plurality of electrode bodies 20 having a five-layer structure called second aluminum foil 2 are continuously formed.
[0017]
In each of the electrode bodies 20 formed in this manner, the positive electrodes and the negative electrodes are electrically connected to each other by the first aluminum foil 1 (positive electrode) and the second aluminum foil 2 (negative electrode). Therefore, it is not necessary to perform conduction between the electrode bodies 20, and the electrode bodies 20 can be formed and laminated with a small number of man-hours. Moreover, by making each material into a bellows shape in advance, handling when the materials are stacked can be facilitated.
[0018]
In order to reduce the contact resistance between the first activated carbon cloth 3 and the first A Rumi foil 1, it is subjected to aluminum spraying on the side in contact with the first aluminum foil 1 of the first activated carbon sheet 3 Is effective (the same applies to the second activated carbon cloth 4 and the second aluminum foil 2). However, when aluminum spraying is performed on the entire surface of the first activated carbon cloth 3, the aluminum sprayed on the folded portion is peeled off in a needle shape when pressed as shown in FIGS. Of aluminum may break through the first activated carbon cloth 3 and the separator 5 to reach the second activated carbon cloth 4. In this case, the first activated carbon cloth 3 and the second activated carbon cloth 4 become defective.
[0019]
Therefore, referring to FIG. 3, when the first activated carbon cloth 3 is bent by performing aluminum spraying only on the portion B excluding the bent portion A of the first activated carbon cloth 3, the above-mentioned is described. Thus, it is possible to prevent the occurrence of defects due to the generation of acicular aluminum. Furthermore, the first activated carbon cloth 3 can be easily bent by not spraying aluminum on the bent portion A in this way.
[0020]
4A, when the first aluminum foil 1 and the first activated carbon cloth 3 are normally bent, the thin (about 0.1 mm) first aluminum foil 1 is bent at an acute angle. The thick activated carbon cloth 3 does not bend at an acute angle. Therefore, if both are overlapped, the folded portion C on the mountain side of the first aluminum foil 1 interferes with the folded portion D on the mountain side of the first activated carbon cloth 3, and the folded portion on the valley side of the first aluminum foil 1. There may be a gap δ between E and the bent portion F on the valley side of the first activated carbon cloth 3. In this case, since the above-described five-layer structure is not formed in the gap δ, the capacity of the electrode body is reduced.
[0021]
Therefore, as shown in FIG. 4 (b), the bent portion C on the mountain side of the first aluminum foil 1 has a curved shape that matches the bent portion D on the mountain side of the first activated carbon cloth 3, It is possible to prevent the gap δ as shown in FIG. 4A from occurring, and to prevent the capacity of the electrode body from decreasing.
[0022]
In the present embodiment, activated carbon cloth made of fibrous activated carbon is used as the activated carbon sheet of the present invention, but powdered, granular, fibrous activated carbon is made of polytetrafluoroethylene (PTFE), A sheet mixed with a binder such as cellulose may be used.
[0023]
Next, a second embodiment of the present invention will be described with reference to FIG. In the present embodiment, as shown in FIG. 5A, the activated carbon cloth piece 41 is attached on one side (corresponding to the surface treatment for forming the activated carbon layer of the present invention) and the thickness is about 0.1 mm. A five-layer electrode body is formed using the aluminum foil 40.
[0024]
And with reference to FIG.5 (b), the activated carbon cloth 41 was stuck to aluminum foil 40 according to the shape of the separator 44 folded in the shape of a bellows similarly to 1st Embodiment mentioned above. A first aluminum foil 42 (corresponding to the first metal foil of the present invention) bent with the side facing inward, and a second aluminum foil 43 bent with the surface on which the activated carbon cloth 41 is stuck outward facing (Corresponding to the second metal foil of the present invention) is overlapped and pressed on both sides of the separator 44.
[0025]
Here, with reference to Fig.5 (a), the activated carbon cloth piece 41 is stuck except for the bending part G of the aluminum foil 40 (the 1st aluminum foil 42 and the 2nd aluminum foil 43). Therefore, the first aluminum foil 42 and the second aluminum foil need only be bent only on the thin aluminum foil 40, and can be easily bent.
[0026]
5A, the positions of the aluminum foil 40 and the activated carbon cloth 41 are fixed in advance. Therefore, as shown in FIG. 5B, the first aluminum foil 42, the separator 44, and the second When the aluminum foil 43 is overlapped and press-contacted, the first aluminum foil 42, the aluminum foil portion of the second aluminum foil 43, and the activated carbon cloth portion are not misaligned.
[0027]
Therefore, the aluminum foil portion of the first aluminum foil 42-the activated carbon cloth affixed to the first aluminum foil-the separator 44-the activated carbon cloth affixed to the second aluminum foil-the aluminum foil of the second aluminum foil An electrode body having a five-layer structure called a portion can be formed and stacked while preventing a reduction in charge capacity due to displacement.
[0028]
In the present embodiment, referring to FIG. 5 (a), the activated carbon cloth piece 41 is attached to the aluminum foil 40 to form an activated carbon layer on the surface of the aluminum foil 40. An activated carbon layer may be formed on the surface of the aluminum foil 40 by applying a coating agent containing activated carbon as a main component (masked) except for the bent portion G.
[Brief description of the drawings]
FIG. 1 is an explanatory view of a method for producing a five-layer electrode body.
2 is an explanatory diagram of the structure of an electrode body formed by the manufacturing method of FIG. 1. FIG.
FIG. 3 is an explanatory diagram of metal spraying on activated carbon cloth.
FIG. 4 is an explanatory diagram of a bent shape of an aluminum foil.
FIG. 5 is an explanatory view of a manufacturing method of a five-layer electrode body.
FIG. 6 is an explanatory view of a conventional electrode manufacturing method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... 1st aluminum foil, 2 ... 2nd aluminum foil, 3 ... 1st activated carbon cloth, 4 ... 2nd activated carbon cloth, 5 ... Separator, 20 ... Electrode body, 40 ... Aluminum foil, 41 ... Activated carbon cloth Fragment

Claims (4)

電解質溶液が含浸され、予め所定長ごとに異なる方向に交互に折り返された長尺のセパレータの一方の面に、予め該セパレータの折り曲げ形状に合わせて折り曲げられた長尺の第１の活性炭シートを重ねる工程と、
前記第１の活性炭シートに、予め前記第１の活性炭シートの折り曲げ形状に合わせて折り曲げられた長尺の第１の金属箔を重ねる工程と、
前記セパレータの他方の面に、予め前記セパレータの折り曲げ形状に合わせて折り曲げられた長尺の第２の活性炭シートを重ねる工程と、
前記第２の活性炭シートに、予め前記第２の活性炭シートの折り曲げ形状に合わせて折り曲げられた長尺の第２の金属箔を重ねる工程と、
前記各工程により重ねられた前記セパレータと前記第１の活性炭シートと前記第１の金属箔と前記第２の活性炭シートと前記第２の金属箔を、さらに折り曲げて圧接することにより、前記第１の金属箔と前記第１の活性炭シートと前記セパレータと前記第２の活性炭シートと前記第２の金属箔とからなる５層の電極体を連続して構成する工程とを含むことを特徴とする電気二重層コンデンサの電極製造方法。The electrolyte solution was impregnated on one surface of the separator in advance elongated folded alternately in a different direction for each predetermined length, the first activated carbon sheet of elongated bent to fit the bent shape of the advance the separator and overlaid Ru process,
The first activated carbon sheet, in advance of the first activated carbon sheet folding Ru together first metal foil elongated bent according to the shape process,
And the surface of the other side of the pre-Symbol separator, Ru superimposed second activated carbon sheet of elongated bent to fit the bent shape of the previously said separator step,
The second activated carbon sheet, and advance the Ru superimposed second metal foil elongated bent to fit the second folding shape of activated carbon sheet process,
The separator, the first activated carbon sheet, the first metal foil, the second activated carbon sheet, and the second metal foil, which are stacked in the respective steps, are further bent and press-contacted . A step of continuously forming a five-layer electrode body comprising the metal foil, the first activated carbon sheet, the separator, the second activated carbon sheet, and the second metal foil. An electrode manufacturing method for an electric double layer capacitor. 前記第１の活性炭シートの前記第１の金属箔と接する面に、前記セパレータの折り返し部分に応じて折り返される部分を除いて、金属を溶射する工程を、さらに含むことを特徴とする請求項１記載の電気二重層コンデンサの電極製造方法。2. The method according to claim 1 , further comprising a step of thermally spraying a metal on a surface of the first activated carbon sheet that contacts the first metal foil except a portion that is folded according to a folded portion of the separator. The electrode manufacturing method of the electric double layer capacitor of description. 前記第１の金属箔の山側の折り曲げ部に、前記第１の活性炭シートの山側の折り曲げ部に合わせた婉曲形状を持たせる工程を、さらに含むことを特徴とする請求項１又は請求項２記載の電気二重層コンデンサの電極製造方法。 3. The method according to claim 1, further comprising a step of causing the bent portion on the mountain side of the first metal foil to have a bent shape in accordance with the bent portion on the mountain side of the first activated carbon sheet. Manufacturing method for electric double layer capacitor . 電解質溶液が含浸され、予め所定長ごとに異なる方向に交互に折り返された長尺のセパレータの両面に、予め該セパレータの折り曲げ形状に合わせて折り曲げられた長尺の金属箔であって、該セパレータと接する面に、該セパレータの折り返し部分に応じて折り返される部分を除いて活性炭層を形成する表面処理が施された第１及び第２の金属箔を重ねる工程と、  A long metal foil which is impregnated with an electrolyte solution and is folded in advance according to the folded shape of the separator on both surfaces of a long separator which is alternately folded back in different directions for each predetermined length. On the surface in contact with the first and second metal foils subjected to surface treatment to form an activated carbon layer excluding a portion folded according to the folded portion of the separator;
前記工程により重ねられた前記セパレータと前記第１の金属箔と前記第２の金属箔とを、さらに折り曲げて圧接することにより、前記第１の金属箔と前記第１の金属箔に形成された活性炭層と前記セパレータと前記第２の金属箔に形成された活性炭層と前記第２の金属箔とからなる５層の電極体を連続して構成する工程とを含むことを特徴とする電気二重層コンデンサの電極製造方法。  The separator, the first metal foil, and the second metal foil stacked in the step were further bent and pressed to form the first metal foil and the first metal foil. And a step of continuously forming a five-layer electrode body comprising the activated carbon layer, the separator, the activated carbon layer formed on the second metal foil, and the second metal foil. Electrode manufacturing method for multilayer capacitor.
JP16319799A 1999-06-10 1999-06-10 Electric double layer capacitor Expired - Fee Related JP4248682B2 (en)

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