Improved energy storage device and methods of manufacture

H - Electricity – 01 – M

Patent

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H01M 10/04 (2006.01) H01G 9/00 (2006.01) H01M 2/08 (2006.01) H01M 4/00 (2006.01) H01M 2/16 (2006.01) H01M 6/48 (2006.01) H01M 4/58 (2006.01) H01M 10/40 (2006.01)

Patent

CA 2186265

A dry preunit (10), includes a plurality of cells (110, 112, 114) in a true bipolar configuration, which are stacked and bonded together, to impart to the device an integral and unitary construction. Each cell (114) includes two electrically conductive electrodes (111A, 111B) that are spaced apart by a predetermined distance. The cell (114) also includes two identical dielectric gaskets (121, 123) that are interposed, in registration with each other, between the electrodes (111A, 111B), for separating and electrically 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 conductive coating layer (119, 120) that is formed on one surface of each electrode. The coating layer (119) includes a set of closely spaced-apart peripheral microprotrusions (125), and a set of distally spaced-apart central microprotrusions (127). These microprotrusions (125,127) impart structural 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. Organic polymers in organic solvents are used to seal the edges of electrodes of porous metal oxides, metal nitrides, or metal carbides to reduce or eleminate leakage current. The preparation of metal nitrides and metal carbides are claimed for electrode use.

Une pré-unité sèche (10) comporte une série d'éléments (110, 112, 114) dans une configuration purement bipolaire empilés et liés ensemble de façon à donner au dispositif une structure unitaire. Chacun des éléments (114) comporte deux électrodes (111A, 111B) espacées d'une certaine distance et deux joints diélectriques identiques (121, 123) interposés en correspondance l'un avec l'autre entre les électrodes (111A, 111B) pour les séparer et les isoler électriquement. Lorsque les électrodes (111A, 111B) et les joints diélectriques identiques (121, 123) sont reliés ensemble, il se forme au moins un espace remplissable (130) dans chacun des éléments. Chacun des éléments (114) est recouvert d'un revêtement poreux conducteur (119, 120) formé sur une surface de chaque électrode et comportant un ensemble de microprotubérances périphériques (125) à faible espacement et un ensemble de microprotubérances centrales (127) à large espacement qui en renforcent la structure tout en assurant un supplément d'isolation entre les électrodes. On crée ainsi une unité de stockage d'énergie (10A) du type condensateur en remplissant d'un électrolyte les espaces (130) de la pré-unité sèche (10) et en bouchant ensuite les orifices de remplissage. On utilise des polymères organiques dans des solvants organiques pour colmater les bords des électrodes en oxydes, nitrures ou carbures métalliques poreux afin de réduire ou éliminer les courants de fuite. Le procédé de préparation des nitrures et carbures métalliques des électrodes fait également partie de l'invention.

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