Energy storage device and methods of manufacture

H - Electricity – 01 – M

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H01M 2/14 (2006.01) B05D 1/32 (2006.01) G03F 7/038 (2006.01) H01G 4/002 (2006.01) H01G 9/00 (2006.01) H01M 2/02 (2006.01) H01M 2/08 (2006.01) H01M 2/16 (2006.01) H01M 4/00 (2006.01) H01M 4/04 (2006.01) H01M 6/48 (2006.01) H01M 10/04 (2006.01) H01M 2/36 (2006.01) H01M 4/58 (2006.01)

Patent

CA 2144657

A dry preunit (10), includes a plurality of cells (110, 112, 114) in a true bipolar configuration, which are stacked and bonded together, to im- part to the device an integral and unitary construction. Each cell (114) in- cludes two electrically conductive electrodes (111A, 111B) that are spaced apart by a predetermined distance. The cell (114) also includes two ident- ical dielectric gaskets (121, 123) that are interposed, in registration with each other, between the electrodes (111A, 111B), for separating and elec- trically insulating these electrodes. When the electrodes (111A, 111B), and the gaskets (121, 123) are bonded together, at least one fill gap (130) is formed for each cell. Each cell (114) also includes a porous and conduc- tive coating layer (119, 120) that is formed on one surface of each elec- trode. The coating layer (119) includes a set of closely spaced-apart peri- pheral microprotrusions (125), and a set of distally spaced-apart central microprotrusions (127). These microprotrusions (125, 127) impart structu- ral support to the cells, and provide additional insulation between the electrodes. An energy storage device (10A) such as a capacitor, is created with the addition of an electrolyte to the gap (130) of the dry preunit (10) and subsequent sealing of the fill ports.

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