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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; Crawford, Robert W.;
Assignee: Maxwell Technologies, Inc. (San Diego, CA)
Primary Examiner: Nguyen; Ha Tran
Assistant Examiner:
Attorney, Agent or Firm: Lebens; Thomas F. Fitch, Even, Tabin & Flannery
A method of making a double layer capacitor consists of the steps of: impregnating each of a plurality of carbon preforms with a metal; forming a plurality of current collector foils, each of the plurality of current collector foils having a tab portion and a paddle portion; forming a plurality of electrodes by positioning one of the plurality of carbon preforms against respective paddle portions of each of the plurality of current collector foils, wherein each of the plurality of electrodes comprises one of the plurality of current collector foils and one of the plurality of carbon preforms; stacking each of the plurality of electrodes such that tab portions of adjacent ones of the plurality of current collector foils are offset, thereby forming an electrode stack; interposing respective porous separator portions between each of the plurality of electrodes, wherein the porous separator portions function as electrical insulators between the adjacent ones of the plurality of electrodes preventing electrical shorting against each other; applying a modest constant pressure against the electrode stack; saturating the electrode stack with an electrolytic solution; and maintaining the electrode stack immersed within the electrolytic solution. |
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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 invention as described is not limited to using molten aluminum, and can use another suitable metal, such as copper or titanium.
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
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