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Energy storage device and its methods of manufacture
| Details |
Inventors: Tsai, K. C.; Mason, Gary E.; Goodwin, Mark L.;
Assignee: Pinnacle Research Institute, Inc. (Los Gatos, CA)
Primary Examiner: Lusignan; Michael
Assistant Examiner:
Attorney, Agent or Firm: Peters, Verny, Jones & Biksa, L.L.P.
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. |
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Definitions The definitions of the following terms are not intended to be exclusive: "Cord" refers to the thin strips of material included in the method of manufacture of the dry preunit.
After initial heating, the removal of the cord produces the open fill ports.
The cord is usually thin, between about 0.
05 and 10 mils, preferably between about 0.
1 and 8 mils with a width between about 1 and 50 mil, preferably between about 10 and 25 mils.
"Electrically conducting support material" refers to any electrically conducting metal or metal alloy, electrically conducting polymer, electrically conducting ceramic, electrically conducting glass, or combinations thereof.
Metals and metal alloys are preferred for producing stock units.
Metals and metal alloys include, but are not limited to titanium, tantalum, niobium, zirconium, iron, copper, lead, tin, nickel, zinc or combinations thereof.
Tantalum and its alloys are preferred for higher temperature applications.
The support material should have a conductivity of greater than about 10.
sup.
-4 S/cm.
"Second electrically conducting material" (having a high surface area) refers to a porous electrode coating which may be of the same or different composition on each side of the support material.
Preferred metal oxides of the present invention include those independently selected from tin, lead, vanadium, titanium, ruthenium, tantalum, rhodium, osmium, iridium, iron, cobalt, nickel, copper, molybdenum, niobium, chromium, manganese, lanthanum, or lanthanum series metals or alloys or combinations thereof, and possibly containing additives like calcium to increase electrical conductivity.
"Electrolyte" refers to an ionically conductive aqueous or non-aqueous solution or material, which enables the dry preunit to be electrically charged.
"Cab-O-Sil.
RTM.
" refers to silica filler available from Cabot Corporation of Tuscola, Ill.
A variety of sizes are available.
"Epoxy" refers to the conventional definition of the product which is an epoxy resin mixed with a specific curing agent, usually a polyamine or polyepoxide mixed with a polyamine curing agent
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Metal Working 
