WO2009042649A1 - Multi electrode series connected arrangement supercapacitor - Google Patents
Multi electrode series connected arrangement supercapacitor Download PDFInfo
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- WO2009042649A1 WO2009042649A1 PCT/US2008/077460 US2008077460W WO2009042649A1 WO 2009042649 A1 WO2009042649 A1 WO 2009042649A1 US 2008077460 W US2008077460 W US 2008077460W WO 2009042649 A1 WO2009042649 A1 WO 2009042649A1
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- stack
- edlc
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- electrode assemblies
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 35
- 230000000712 assembly Effects 0.000 claims abstract description 30
- 238000000429 assembly Methods 0.000 claims abstract description 30
- 239000003792 electrolyte Substances 0.000 claims abstract description 25
- 239000003990 capacitor Substances 0.000 claims abstract description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 10
- 229910052782 aluminium Inorganic materials 0.000 description 10
- WEVYAHXRMPXWCK-UHFFFAOYSA-N Acetonitrile Chemical compound CC#N WEVYAHXRMPXWCK-UHFFFAOYSA-N 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 229910052799 carbon Inorganic materials 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 229920001684 low density polyethylene Polymers 0.000 description 3
- 239000004702 low-density polyethylene Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000007772 electrode material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 1
- 150000001721 carbon Chemical class 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical class C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Substances N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920003223 poly(pyromellitimide-1,4-diphenyl ether) Polymers 0.000 description 1
- -1 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000012812 sealant material Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/78—Cases; Housings; Encapsulations; Mountings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/30—Electrodes characterised by their material
- H01G11/32—Carbon-based
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/66—Current collectors
- H01G11/72—Current collectors specially adapted for integration in multiple or stacked hybrid or EDL capacitors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/76—Terminals, e.g. extensions of current collectors specially adapted for integration in multiple or stacked hybrid or EDL capacitors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/26—Electrodes characterised by their structure, e.g. multi-layered, porosity or surface features
- H01G11/28—Electrodes characterised by their structure, e.g. multi-layered, porosity or surface features arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/30—Electrodes characterised by their material
- H01G11/32—Carbon-based
- H01G11/34—Carbon-based characterised by carbonisation or activation of carbon
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G11/66—Current collectors
- H01G11/70—Current collectors characterised by their structure
-
- 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
Definitions
- the invention pertains to electrochemical double layer capacitor devices and, more particularly, to a device fabricated using multiple series connected electrode assemblies within a single cell to form a predetermined voltage standoff.
- Direct current electronic circuits and devices that are manufactured today have specific voltage requirements for proper operation. Nominal voltages can range from 1.2 volts to hundreds of volts. The power supply, or source, must match the load requirements.
- Symmetrical, bipolar electrochemical double layer capacitors are constructed by alternately layering electrode material and separators, forming the electrode assembly a stacked structure.
- the electrode material is generally made, starting with capacitor grade aluminum.
- An activated carbon mixture is deposited or laminated on top and bottom, forming a double- sided electrode. Two of these electrodes are used, one being the positive and the other being the negative side of a simple cell.
- the separator is used to electrically isolate the two electrodes and also as the conductor for electrically charged protons.
- the completed electrode assembly is then placed in a canister with an electrolyte and then sealed becoming a one-cell structure.
- Electrolytes used today are available in two different forms: aqueous and aprotic.
- Aqueous electrolytes generally have a working window of 1.0 to 1.2 volts, per cell.
- Aprotic, or dampened-wetted, electrolytes have a range of 2.2 to 4.6 working volts, per cell.
- an Acetonitrile solvent is used with a quanterry salt of 1.
- the Helmholtz layer is only several angstroms thick and is formed between the current collector and activated carbon. It is in this region that charged particles, negative or positive, transfer their charge to the current collector. In a neutral solution state, or a non-charged state, the electrolyte has an evenly distributed zero charge. As the electrode assembly structure gains or loses charge, the movement of charge separates individually to its own polarity terminal. The charge concentration penetrates the activated carbon material composite into the Helmholtz region to varying degrees . The level of electrolyte charge concentration is minimum at the separator and maximum at the Helmholtz region.
- an electrochemical double layer capacitor (EDLC) single cell with electrolyte, incorporating series electrode assemblies to provide an increased voltage stack.
- the series voltage stack has essentially individual electrode assemblies electrically concatenated together in series.
- the electrodes have a double-sided activated carbon composition formed on a capacitor grade aluminum current collector.
- the EDLC stack has a number of segments and mass free zones separating them. The segments are folded so that mass free zones are disposed at the apex of each fold. Power tabs, plus and minus, are connected to the end extensions of the electrode assemblies. Monitor/control tabs are operatively attached and extended from the series connected segments.
- a poly bag as a single cell, contains the electrolyte and the electrode assemblies. Power and monitor/control tabs are operatively extended from the electrode assemblies.
- the EDLC stack has a number of segments and mass free zones separating them. The segments are folded so that mass free zones are disposed at the apex of each fold.
- FIGURE Ia is a front view of the components of a single EDLC device of the prior art
- FIGURE Ib is a side view of the single EDLC device of FIGURE Ia assembled
- FIGURE 2 is an illustration of 12-volt EDLC unit with external monitor/control leads,-
- FIGURE 3 is an illustration of the front side, top and bottom side of two electrodes specifically manufactured for an integrated assembly of a 12 volt stacked arrangement
- FIGURE 4 is an illustration of the backside, top and bottom side of two electrodes specifically manufactured for an integrated assembly of a 12 volt stacked arrangement
- FIGURE 5 is an illustration of a complete 12 volt series electrode assembly showing power and monitor/control voltage taps incorporated into the folding scheme,- and
- FIGURE 6 is an illustration of a completed single cell series connected 12-volt device packaged within a poly bag container with power and monitor/control lead extensions.
- the invention is a symmetrical bipolar electrochemical double layer capacitor device.
- a series multiple voltage stack has electrode assemblies electrically connected in series.
- the electrode assemblies have a double-sided activated carbon electrode formed on a current collector.
- a poly bag is used to contain the electrolyte and the electrode assemblies.
- FIGs 1 Individual EDLC electrodes and required separator 10 is shown in Figures 1 and the completed assembly 20 in Figure Ib.
- a typical electrolyte window of 2.7-volts (IM TEABF 4 /ACN) of the EDLC electrode assembly 20 is divided into the required voltage needed by the application. The primary consideration is that the electrolyte depends only on the first electrode assembly and its electrolyte voltage window when considering a series string of EDLCs.
- Electrodes 11, 12 are disposed parallel to each other, as shown. Separators 13 and 14 extend between and beneath the two electrodes 11, 12. A negative bare aluminum foil tab 16 and a positive bare aluminum foil tab 15 extend from the respective electrodes 12, 11. Although the electrodes 11, 12 and separators 13, 14 are shown offset from each other in Figure Ia, this depiction is only illustrative. Electrodes 11, 12 are rolled from bottom to top, leaving terminal tabs 15, 16, respectively, exposed 180° from each other.
- top view of EDLC electrodes 10 shows negative and positive tabs 16, 15, respectively.
- Separators 14, 13 electrically isolate electrodes 12, 11.
- Kapton tape 21 binds the package of electrodes 12, 11 and separators 14, 13, like a sandwich.
- the amount of activated carbon and composite material used in fabricating the single EDLC 10, 20 is dependent on the required capacitance of the total cell.
- FIG 2 there is shown a single EDLC device 10 using only one electrolyte 43, not shown, for an entire structure comprising five concatenated electrode assemblies, 34-38.
- the voltage monitor/control tabs 39-42 are extended external to the pouch bag 31.
- the power tabs 32, 33 and voltage control ⁇ monitor tabs 39-42 provide the complete electrical interface.
- Figure 2 shows a complete 12 -volt EDLC in a poly bag package.
- Poly bag 31 is constructed with multiple layers, not shown. Poly bag 31 provides a lightweight, puncture resistant, airtight seal having a long service factor and being chemically indifferent to the electrolyte used within this embodiment. Poly bag 31 also has a small form factor since all gas can be replaced with nitrogen, then purged and supplemented with electrolyte to form a vacuum tight seal.
- the sealant material is a linear, low-density polyethylene that reforms below 12O 0 C. A low-density polyethylene layer is then applied and used as a tie layer. Tie layers are very thin layers binding and holding two different materials together. Copper is used as the chemically non-reactive foil layer to moisture-proof the assembly. The copper is sandwiched between another low-density polyethylene tie layer.
- the outermost, puncture resistant material is a layer of polyethylene terephthalate .
- a specific voltage standoff EDLC need not necessarily have individual electrode assemblies separately made and connected by welding, such as shown in the preferred embodiment ( Figure 2) .
- the two electrodes required for each electrode assembly encompassed into a single cell EDLC can be manufactured to accommodate separate activated carbon partitions, this being the individual electrode assemblies in series on the current collector capacitor grade aluminum.
- Figure 3 illustrates the front, top and bottom views of two electrodes on one side of a complete EDLC unit, Figure 5, whereas Figure 4 illustrates the backside, top and bottom views thereof.
- a fold line 53 ( Figure 3) indicates where the top and bottom portions of the electrode arrangement are folded.
- folded line 53 indicates the location at which the top and bottom electrodes 50a are folded and overlap.
- the 12 -volt manufactured electrode of Figures 3 and 4 has a total of ten activated carbon pads on each side of the electrode that are carbon isolated from each other.
- the tabs of Figures 3 and 4 can be color coded to indicate the specific voltage polarity segments.
- Figures 3 and 4 show both the front and back of the device, activated carbon pads segmented areas being imprinted onto two aluminum current collectors of which a two-electrode structure can be configured for a 12 -volt stack.
- Other electrode arrangements can also be configured for larger and smaller voltage stack arrangements as desired.
- the capacitance of each pad and its arrangement on the current collector determines the total cell capacitance.
- the activated carbon mix has a specific capacitance associated with its inherent physical properties, such as pore size and pore size distribution.
- the carbon loading and specific capacitance yields the desired capacitance in farads per cubic centimeter, F/cm 3 . Since the application voltage standoff dictates the volumetric pad size, the volume of the pad must be calculated, LxWxH. An individual pad is designed and duplicated to populate the entire current collector interface.
- pad areas of the carbon composite on the current collector must be identified to ensure voltage isolation between the individual electrode terminals. Areas 54-57 are clean cut or foil free relative the rest of the assembly.
- the single electrode aluminum current collector structure as depicted in Figures 3 and 4 is first made by layering a thin coating of specially formulated activated carbons and binder combination, not shown, onto an aluminum current collector.
- the capacitance is designed into electrodes 50, 50a by the physical area of carbon applied, LxWxH. Mass-free zones 58- 61 are carbonless and are used as the folding points, along with the clean cut areas 54-57 for the series electrode voltage stages.
- Two separate and physically different electrodes are provided, one being the positive and one being a negative electrode.
- the unique folding scheme creates five segments in series for a single cell double layer capacitor. Since each electrode has carbon composites on both sides, the bipolar carbon composite layout for each electrode (Figure 3) matches the alternate electrical pole ( Figure 4) precisely.
- the material for poly bag 92 ( Figure 6) is cut into the desired shape of the electrode assembly 81 with provisions made for extension of the poly bag material to extend beyond the electrode assembly edge, providing a better seal around the tabbed leads 94 (62,66), 95 (63,67), 96 (64,68), and 97 (65,69) .
- the total number of extensions in the 12 volt assembly 80 protruding to the outside of the poly bag 92 includes power 71 and ground 52 with four tabs 94-97 for the individual connections to the series stack..
- the individual series cell aluminum tabs are sonically welded to copper or aluminum flat stock materials, which are brought out through the poly bag 92.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Electric Double-Layer Capacitors Or The Like (AREA)
Abstract
The present invention is an electrochemical double layer capacitor (EDLC) series stack formed into a single electrolyte cell structure. The concatenated multiple electrode assembly stack has electrode assemblies electrically connected in series. The electrode assemblies have a double-sided activated carbon electrode formed on a current collector. Power tabs are connected to the end electrode assemblies. An electrolyte is also provided. A poly bag contains the electrolyte and the electrode assemblies. The electrode assemblies form a double-sided activated-carbon electrode on a current collector. The EDLC stack has a number of segments and mass free zones separating them. The segments are folded so that mass free zones are disposed at the apex of each fold.
Description
MULTI ELECTRODE SERIES CONNECTED ARRANGEMENT SUPERCAPACITOR
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to and is a continuation of U.S. Nonprovisional Patent Application Serial No. 11/903,929, entitled "Multi Electrode Series Connected Arrangement Supercapacitor, " filed September 25, 2007, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The invention pertains to electrochemical double layer capacitor devices and, more particularly, to a device fabricated using multiple series connected electrode assemblies within a single cell to form a predetermined voltage standoff.
BACKGROUND OF THE INVENTION
Direct current electronic circuits and devices that are manufactured today have specific voltage requirements for proper operation. Nominal voltages can range from 1.2 volts to hundreds of volts. The power supply, or source, must match the load requirements.
Until recently only chemical batteries with specific voltage windows were suitable for certain applications. The most common battery is the 1.5-volt single cell. In order to obtain larger voltage limits, individual battery cells
must be stacked, or concatenated in series, plus to minus to plus to minus etc. Combining individual cells into battery packs has therefore been the conventional solution to overcoming the voltage limitation of single cells. Larger batteries are merely a collection of smaller, in-series, single battery cells placed in one container with single input and output terminals.
Symmetrical, bipolar electrochemical double layer capacitors, or EDLCs, are constructed by alternately layering electrode material and separators, forming the electrode assembly a stacked structure. The electrode material is generally made, starting with capacitor grade aluminum. An activated carbon mixture is deposited or laminated on top and bottom, forming a double- sided electrode. Two of these electrodes are used, one being the positive and the other being the negative side of a simple cell. The separator is used to electrically isolate the two electrodes and also as the conductor for electrically charged protons. Typically, the completed electrode assembly is then placed in a canister with an electrolyte and then sealed becoming a one-cell structure.
Until now, as with chemical batteries, individual EDLC cells must operate within specific voltage ranges dictated by the choice of electrolyte. Electrolytes used today are available in two different forms: aqueous and aprotic. Aqueous electrolytes generally have a working window of 1.0 to 1.2 volts, per cell. Aprotic, or dampened-wetted,
electrolytes, however, have a range of 2.2 to 4.6 working volts, per cell. In this disclosure, an Acetonitrile solvent is used with a quanterry salt of 1. OM TEABF4.
It is well known to electrochemists that charged ionic transfer occurs primarily in one region, namely the Helmholtz layer. This layer is only several angstroms thick and is formed between the current collector and activated carbon. It is in this region that charged particles, negative or positive, transfer their charge to the current collector. In a neutral solution state, or a non-charged state, the electrolyte has an evenly distributed zero charge. As the electrode assembly structure gains or loses charge, the movement of charge separates individually to its own polarity terminal. The charge concentration penetrates the activated carbon material composite into the Helmholtz region to varying degrees . The level of electrolyte charge concentration is minimum at the separator and maximum at the Helmholtz region.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an electrochemical double layer capacitor (EDLC) single cell, with electrolyte, incorporating series electrode assemblies to provide an increased voltage stack. The series voltage stack has essentially individual electrode assemblies electrically concatenated together in series. The electrodes have a double-sided activated carbon
composition formed on a capacitor grade aluminum current collector.
The EDLC stack has a number of segments and mass free zones separating them. The segments are folded so that mass free zones are disposed at the apex of each fold. Power tabs, plus and minus, are connected to the end extensions of the electrode assemblies. Monitor/control tabs are operatively attached and extended from the series connected segments. In one embodiment, a poly bag, as a single cell, contains the electrolyte and the electrode assemblies. Power and monitor/control tabs are operatively extended from the electrode assemblies. The EDLC stack has a number of segments and mass free zones separating them. The segments are folded so that mass free zones are disposed at the apex of each fold.
BRIEF DESCRIPTION OF THE DRAWINGS
Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIGURE Ia is a front view of the components of a single EDLC device of the prior art;
FIGURE Ib is a side view of the single EDLC device of FIGURE Ia assembled;
FIGURE 2 is an illustration of 12-volt EDLC unit with external monitor/control leads,-
FIGURE 3 is an illustration of the front side, top and bottom side of two electrodes specifically manufactured for an integrated assembly of a 12 volt stacked arrangement;
FIGURE 4 is an illustration of the backside, top and bottom side of two electrodes specifically manufactured for an integrated assembly of a 12 volt stacked arrangement;
FIGURE 5 is an illustration of a complete 12 volt series electrode assembly showing power and monitor/control voltage taps incorporated into the folding scheme,- and
FIGURE 6 is an illustration of a completed single cell series connected 12-volt device packaged within a poly bag container with power and monitor/control lead extensions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is a symmetrical bipolar electrochemical double layer capacitor device. A series multiple voltage stack has electrode assemblies electrically connected in series. The electrode assemblies have a double-sided activated carbon electrode formed on a current collector. A poly bag is used to contain the electrolyte and the
electrode assemblies.
Two embodiments have been developed for increasing the voltage standoff of a single cell device typically rated at 2.7-volts. Although a 12-volt cell is described herein, it should be understood that any other voltage can be obtained including, but not limited to 12-volt cells.
Individual EDLC electrodes and required separator 10 is shown in Figures 1 and the completed assembly 20 in Figure Ib. A typical electrolyte window of 2.7-volts (IM TEABF4/ACN) of the EDLC electrode assembly 20 is divided into the required voltage needed by the application. The primary consideration is that the electrolyte depends only on the first electrode assembly and its electrolyte voltage window when considering a series string of EDLCs.
Two double sided activated carbon electrodes 11 and 12 are disposed parallel to each other, as shown. Separators 13 and 14 extend between and beneath the two electrodes 11, 12. A negative bare aluminum foil tab 16 and a positive bare aluminum foil tab 15 extend from the respective electrodes 12, 11. Although the electrodes 11, 12 and separators 13, 14 are shown offset from each other in Figure Ia, this depiction is only illustrative. Electrodes 11, 12 are rolled from bottom to top, leaving terminal tabs 15, 16, respectively, exposed 180° from each other.
Referring now also to Figure Ib, top view of EDLC electrodes 10 shows negative and positive tabs 16, 15,
respectively. Separators 14, 13 electrically isolate electrodes 12, 11. Kapton tape 21 binds the package of electrodes 12, 11 and separators 14, 13, like a sandwich. The amount of activated carbon and composite material used in fabricating the single EDLC 10, 20 is dependent on the required capacitance of the total cell.
Referring now to Figure 2, there is shown a single EDLC device 10 using only one electrolyte 43, not shown, for an entire structure comprising five concatenated electrode assemblies, 34-38. The voltage monitor/control tabs 39-42 are extended external to the pouch bag 31. The power tabs 32, 33 and voltage control\monitor tabs 39-42 provide the complete electrical interface. Figure 2 shows a complete 12 -volt EDLC in a poly bag package.
Using an electrolyte with 1.0 M of TEABF4 in Acetonitrile limits the voltage to 2.7 volts. This now becomes the determining factor for the total number of electrode assemblies required for the entire stack 30. For example, a 12-volt cell requires five assemblies, as shown. The current collector interface tabs between electrode assemblies are sonically welded 32 to minimize electrical lead resistance.
It is difficult to manufacture individual electrodes to contain the exact amount of capacitance so that all assemblies in the stack are identical. It is for this reason monitor/control terminal tabs 39-42 are available
externally.
Poly bag 31 is constructed with multiple layers, not shown. Poly bag 31 provides a lightweight, puncture resistant, airtight seal having a long service factor and being chemically indifferent to the electrolyte used within this embodiment. Poly bag 31 also has a small form factor since all gas can be replaced with nitrogen, then purged and supplemented with electrolyte to form a vacuum tight seal. The sealant material is a linear, low-density polyethylene that reforms below 12O0C. A low-density polyethylene layer is then applied and used as a tie layer. Tie layers are very thin layers binding and holding two different materials together. Copper is used as the chemically non-reactive foil layer to moisture-proof the assembly. The copper is sandwiched between another low-density polyethylene tie layer. The outermost, puncture resistant material is a layer of polyethylene terephthalate .
A specific voltage standoff EDLC need not necessarily have individual electrode assemblies separately made and connected by welding, such as shown in the preferred embodiment (Figure 2) . The two electrodes required for each electrode assembly encompassed into a single cell EDLC can be manufactured to accommodate separate activated carbon partitions, this being the individual electrode assemblies in series on the current collector capacitor grade aluminum.
Figure 3 illustrates the front, top and bottom views of
two electrodes on one side of a complete EDLC unit, Figure 5, whereas Figure 4 illustrates the backside, top and bottom views thereof. A fold line 53 (Figure 3) indicates where the top and bottom portions of the electrode arrangement are folded. Similarly, in Figure 4, folded line 53 indicates the location at which the top and bottom electrodes 50a are folded and overlap.
The 12 -volt manufactured electrode of Figures 3 and 4 has a total of ten activated carbon pads on each side of the electrode that are carbon isolated from each other. The tabs of Figures 3 and 4 can be color coded to indicate the specific voltage polarity segments. Figures 3 and 4 show both the front and back of the device, activated carbon pads segmented areas being imprinted onto two aluminum current collectors of which a two-electrode structure can be configured for a 12 -volt stack. Other electrode arrangements can also be configured for larger and smaller voltage stack arrangements as desired.
The capacitance of each pad and its arrangement on the current collector determines the total cell capacitance. The activated carbon mix has a specific capacitance associated with its inherent physical properties, such as pore size and pore size distribution. The carbon loading and specific capacitance yields the desired capacitance in farads per cubic centimeter, F/cm3. Since the application voltage standoff dictates the volumetric pad size, the volume of the pad must be calculated, LxWxH. An individual
pad is designed and duplicated to populate the entire current collector interface.
Referring to Figures 3 and 4, pad areas of the carbon composite on the current collector must be identified to ensure voltage isolation between the individual electrode terminals. Areas 54-57 are clean cut or foil free relative the rest of the assembly.
Referring now to Figures 5 and 6, the single electrode aluminum current collector structure as depicted in Figures 3 and 4 is first made by layering a thin coating of specially formulated activated carbons and binder combination, not shown, onto an aluminum current collector. The capacitance is designed into electrodes 50, 50a by the physical area of carbon applied, LxWxH. Mass-free zones 58- 61 are carbonless and are used as the folding points, along with the clean cut areas 54-57 for the series electrode voltage stages. Two separate and physically different electrodes are provided, one being the positive and one being a negative electrode. The unique folding scheme creates five segments in series for a single cell double layer capacitor. Since each electrode has carbon composites on both sides, the bipolar carbon composite layout for each electrode (Figure 3) matches the alternate electrical pole (Figure 4) precisely.
The material for poly bag 92 (Figure 6) is cut into the desired shape of the electrode assembly 81 with provisions made for extension of the poly bag material to extend beyond
the electrode assembly edge, providing a better seal around the tabbed leads 94 (62,66), 95 (63,67), 96 (64,68), and 97 (65,69) . The total number of extensions in the 12 volt assembly 80 protruding to the outside of the poly bag 92 includes power 71 and ground 52 with four tabs 94-97 for the individual connections to the series stack.. The individual series cell aluminum tabs are sonically welded to copper or aluminum flat stock materials, which are brought out through the poly bag 92.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
Claims
1. An electrochemical double layer capacitor (EDLC) stack comprising: a) a series multiple voltage stack comprising a plurality of electrode assemblies electrically connected in series, said electrode assemblies comprising a double- sided activated carbon electrode formed on a current collector; b) an electrolyte; and c) a poly bag for containing said electrolyte and said plurality of electrode assemblies.
2. The EDLC stack in accordance with claim 1, further comprising power tabs operatively connected to said plurality of electrode assemblies.
3. The EDLC stack in accordance with claim 1, wherein said poly bag provides an external interface for said cell stack.
4. The EDLC stack in accordance with claim 1, wherein said electrode assemblies comprise a double-sided activated carbon electrode formed on a current collector.
5. The EDLC stack in accordance with claim 1, wherein said EDLC stack comprises a plurality of segments and further comprising a plurality of mass free zones separating said plurality of segments.
6. The EDLC stack in accordance with claim 5, wherein said plurality of segments is folded so that said mass free zones are disposed at the apex of said folds.
7. The EDLC stack in accordance with claim 1, wherein said poly bag is shaped to conform to said EDLC stack.
8. The EDLC stack in accordance with claim 1, wherein said poly bag comprises a one cell structure having one electrolyte source for accommodating a plurality of variant voltage stacks, thereby yielding a variant of different terminal voltage limits.
9. An electrochemical double layer capacitor (EDLC) stack comprising: a) a series multiple voltage stack comprising a plurality of electrode assemblies electrically connected in series; b) an electrolyte; and c) a poly bag for containing said plurality of electrode assemblies.
10. The EDLC stack in accordance with claim 9, further comprising power tabs operatively connected to said plurality of electrode assemblies.
11. The EDLC stack in accordance with claim 9, wherein said poly bag provides an external interface for said cell stack.
12. The EDLC stack in accordance with claim 9, wherein said electrode assemblies comprise a double-sided activated carbon electrode formed on a current collector.
13. The EDLC stack in accordance with claim 9, wherein said EDLC stack comprises a plurality of segments and further comprising a plurality of mass free zones separating said plurality of segments.
14. The EDLC stack in accordance with claim 13, wherein said plurality of segments is folded so that said mass free zones are disposed at the apex of said folds.
15. The EDLC stack in accordance with claim 9, wherein said poly bag is shaped to conform to said EDLC stack.
16. The EDLC stack in accordance with claim 9, wherein said poly bag is a one cell structure containing one electrolyte source which can accommodate a multitude of variant voltage stacks thereby yielding a variant of different terminal voltage limits.
Priority Applications (2)
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EP08834022.9A EP2193532A4 (en) | 2007-09-25 | 2008-09-24 | Multi electrode series connected arrangement supercapacitor |
CN200880115065A CN101849271A (en) | 2007-09-25 | 2008-09-24 | Multi electrode series connected arrangement supercapacitor |
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US11/903,929 | 2007-09-25 | ||
US11/903,929 US7830646B2 (en) | 2007-09-25 | 2007-09-25 | Multi electrode series connected arrangement supercapacitor |
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WO2009042649A1 true WO2009042649A1 (en) | 2009-04-02 |
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PCT/US2008/077460 WO2009042649A1 (en) | 2007-09-25 | 2008-09-24 | Multi electrode series connected arrangement supercapacitor |
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US (2) | US7830646B2 (en) |
EP (1) | EP2193532A4 (en) |
CN (1) | CN101849271A (en) |
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Also Published As
Publication number | Publication date |
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CN101849271A (en) | 2010-09-29 |
US7830646B2 (en) | 2010-11-09 |
US20090080141A1 (en) | 2009-03-26 |
US8098483B2 (en) | 2012-01-17 |
US20110032661A1 (en) | 2011-02-10 |
EP2193532A4 (en) | 2017-03-22 |
EP2193532A1 (en) | 2010-06-09 |
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