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Method of making a multi-electrode double layer capacitor having single electrolyte seal and aluminum-impregnated carbon cloth electrodes
| Details |
Inventors: Farahmandi, C. Joseph; Dispennette, John M.; Blank, Edward; Kolb, Alan C.;
Assignee: Maxwell Energy Products, Inc. (San Diego, CA)
Primary Examiner: Harrison; Jessica J.
Assistant Examiner: Trinh; Minh
Attorney, Agent or Firm: Fitch, Even, Tabin & Flannery
A method of making a double layer capacitior includes first and second flat stacks of electrodes adapted to be housed in a closeable two-part capacitor case which includes only a single electrolyte seal. Each electrode stack has a plurality of electrodes connected in parallel, with the electrodes of one stack being interleaved with the electrodes of the other stack to form an interleaved stack, and with the electrodes of each stack being electrically connected to respective capacitor terminals. A porous separator is positioned against the electrodes of one stack before interleaving to prevent electrical shorts between the electrodes. The electrodes are made by folding a compressible, low resistance, aluminum-impregnated carbon cloth, made from activated carbon fibers, around a current collector foil, with a tab of the foils of each electrode of each stack being connected in parallel and connected to the respective capacitor terminal. The height of the interleaved stack is somewhat greater than the inside height of the closed capacitor case, thereby requiring compression of the interleaved electrode stack when placed inside of the case, and thereby maintaining the interleaved electrode stack under modest constant pressure. The closed capacitor case is filled with an electrolytic solution and sealed. A preferred electrolytic solution is made by dissolving an appropriate salt into acetonitrile (CH.sub.3 CN). In one embodiment, the two arts of the capacitor case are conductive and function as the capacitor terminals. |
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DETAILED DESCRIPTION OF THE INVENTION The following description of the presently contemplated best mode of practicing the invention is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention.
The scope of the invention should be determined with reference to the claims.
Referring to FIG.
1, a single cell, high performance double layer capacitor 10 is illustrated including a cell holder 11, a pair of aluminum/carbon composite electrodes 12 and 14, an electronic separator 18, an electrolyte 20, a pair of current collector plates 22 and 24, and electrical leads 28 and 29, extending from the current collector plates 22 and 24.
The pair of aluminum/carbon composite electrodes 12 and 14 are preferably formed from a porous carbon cloth preform or carbon paper preform which is impregnated with molten aluminum.
The porosity of the aluminum/carbon composite electrodes 12 and 14 must be closely controlled during the impregnation process to subsequently permit a sufficient amount of the electrolyte 20 to be introduced into the double layer capacitor 10 and penetrate the pores of the carbon fibers.
The pair of current collector plates 22 and 24 are attached to the back of each aluminum/carbon composite electrode 12 and 14.
Preferably, the current collector plates 22 and 24 are thin layers of aluminum foil.
An electronic separator 18 is placed between the opposing aluminum/carbon composite electrodes 12 and 14.
The electronic separator 18 is preferably made from a highly porous material which acts as an electronic insulator between the aluminum/carbon composite electrodes 12 and 14.
The purpose of the electronic separator 18 is to assure that the opposing electrodes 12 and 14 are never in contact with one another.
Contact between electrodes results in a short circuit and rapid depletion of the charges stored in the electrodes.
The porous nature of the electronic separator 18 allows movement of the ions in the electrolyte 20.
The preferred electronic separator 18 is a porous polypropylene or polyethylene sheet approximately 1 mil (0
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Metal Working 
