U.S. patent application number 09/790619 was filed with the patent office on 2002-08-29 for packaging method for electric power storage units of an ultracapacitor energy storage device.
Invention is credited to Huang, Yung-Shang, Lawson, James M., Pong, Wei-Te, Tsai, Keh-Chi, Yang, Chang-Chen.
Application Number | 20020116803 09/790619 |
Document ID | / |
Family ID | 25151255 |
Filed Date | 2002-08-29 |
United States Patent
Application |
20020116803 |
Kind Code |
A1 |
Yang, Chang-Chen ; et
al. |
August 29, 2002 |
PACKAGING METHOD FOR ELECTRIC POWER STORAGE UNITS OF AN
ULTRACAPACITOR ENERGY STORAGE DEVICE
Abstract
A packaging method for electric power storage units of an
ultracapacitor energy storage device. An electrolyte solution is
filled directly during the process of stacking electrodes so as to
omit the steps of partially forming and enclosing a refill port.
Thus, the fabrication process can be effectively simplified and the
production efficiency can be increased. First, an annular glue wall
is coated along the border of the top surface of a first electrode.
The electrolyte solution is filled on the top surface of the first
electrode enclosed by the annular glue wall. A second electrode is
then stacked over the first electrode. The annular glue wall is
heated to bind the first electrode, the second electrode, and the
annular glue wall, thus enclosing the electrolyte solution between
the first electrode and the second electrode.
Inventors: |
Yang, Chang-Chen; (Taipei,
TW) ; Pong, Wei-Te; (Taoyuan Hsien, TW) ;
Huang, Yung-Shang; (Taipei Hsien, TW) ; Tsai,
Keh-Chi; (Saratoga, CA) ; Lawson, James M.;
(Los Gatos, CA) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
25151255 |
Appl. No.: |
09/790619 |
Filed: |
February 23, 2001 |
Current U.S.
Class: |
29/25.03 |
Current CPC
Class: |
H01G 11/80 20130101;
H01G 9/155 20130101; Y02E 60/13 20130101; H01G 11/84 20130101 |
Class at
Publication: |
29/25.03 |
International
Class: |
H01G 009/00 |
Claims
What is claimed is:
1. A packaging method for electric power storage units of an
ultracapacitor energy storage device, which comprises the steps of:
providing a first electrode and coating an annular glue wall along
the border on a top surface of the first electrode; filling an
electrolyte solution on the top surface of the first electrode
enclosed by the annular glue wall; providing a second electrode
stacked on the first electrode; and heating and reflowing the
annular glue wall to bind the first electrode, the second
electrode, and the annular glue wall together and to enclose the
electrolyte solution between the first electrode and the second
electrode.
2. The packaging method of claim 1, wherein the annular glue wall
is composed of a thermal plastic resin.
3. The packaging method of claim 1, wherein the annular glue wall
is formed on the top surface of the first electrode by
printing.
4. The packaging method of claim 3, wherein the step of coating an
annular glue wall comprises the steps of: fixing the first
electrode on a printing tool; and applying half-tone printing on
the top surface of the first electrode.
5. The packaging method of claim 4, wherein the printing tool has a
container whose size and depth are approximately the same of those
of the first electrode so as to accommodate the first
electrode.
6. The packaging method of claim 5, wherein the bottom of the
container has a vacuum hole to suck and hold the first
electrode.
7. The packaging method of claim 1, wherein the step of coating an
annular glue wall is formed using a glue supplier.
8. The packaging method of claim 1, wherein the annular glue wall
is formed by immersing and coating.
9. The packaging method of claim 1, wherein the annular glue wall
is formed by spraying and coating.
10. The packaging method of claim 1, wherein the step of coating an
annular glue wall further comprises the step of speeding up the
binding of the annular glue wall.
11. The packaging method of claim 10, wherein the step of speeding
up the binding of the annular glue wall is achieved by heating.
12. The packaging method of claim 11, wherein the heating is done
using hot air.
13. The packaging method of claim 11, wherein the heating is done
using infrared light.
14. The packaging method of claim 10, wherein the step of speeding
up the binding of the annular glue wall is achieved using
ultraviolet light.
15. The packaging method of claim 10, wherein the step of speeding
up the binding of the annular glue wall is achieved using
radiation.
16. The packaging method of claim 1, wherein the step of filling an
electrolyte solution further comprises the step of placing an
separating plate on the top surface of the first electrode.
17. The packaging method of claim 16, wherein the separating plate
is porous and acid-resistant.
18. The packaging method of claim 16, wherein the separating plate
is a glass fiber plate.
19. The packaging method of claim 1, wherein the step of reflowing
the glue wall is done by heating the annular glue wall using a heat
source.
20. The packaging method of claim 19, wherein the heat source is an
ultrasonic wave.
21. The packaging method of claim 19, wherein the heat source is
hot air.
22. The packaging method of claim 19, wherein the heat source is
infrared light.
23. A packaging method for electric power storage units of an
ultracapacitor energy storage device, which comprises the steps of:
providing a first electrode and coating a first annular glue wall
along the border on a top surface of the first electrode, providing
a second electrode and coating a second annular glue wall along the
border on a bottom surface of the first electrode with the second
annular glue wall corresponding to the first annular glue wall;
filling an electrolyte solution on the top surface of the first
electrode enclosed by the annular glue wall; stacking the second
electrode on the first electrode; and heating and reflowing the
first annular glue wall and the second annular glue wall to bind
the first electrode, the second electrode, the first annular glue
wall, and the second annular glue wall together and to enclose the
electrolyte solution between the first electrode and the second
electrode.
24. The packaging method of claim 23, wherein the first annular
glue wall is composed of a thermal plastic resin.
25. The packaging method of claim 23, wherein the first annular
glue wall is formed on the top surface of the first electrode by
printing.
26. The packaging method of claim 25, wherein the step of coating
an annular glue wall comprises the steps of: fixing the first
electrode on a printing tool; and applying half-tone printing on
the top surface of the first electrode.
27. The packaging method of claim 26, wherein the printing tool has
a container whose size and depth are approximately the same of
those of the first electrode so as to accommodate the first
electrode.
28. The packaging method of claim 27, wherein the bottom of the
container has a vacuum hole to suck and hold the first
electrode.
29. The packaging method of claim 23, wherein the step of coating a
first annular glue wall is formed using a glue supplier.
30. The packaging method of claim 23, wherein the first annular
glue wall is formed by immersing and coating.
31. The packaging method of claim 23, wherein the first annular
glue wall is formed by spraying and coating.
32. The packaging method of claim 23, wherein the step of coating a
first annular glue wall further contains the step of speeding up
the binding of the first annular glue wall.
33. The packaging method of claim 32, wherein the step of speeding
up the binding of the first annular glue wall is achieved by
heating.
34. The packaging method of claim 33, wherein the heating is done
using hot air.
35. The packaging method of claim 33, wherein the heating is done
using infrared light.
36. The packaging method of claim 32, wherein the step of speeding
up the binding of the first annular glue wall is achieved using
ultraviolet light.
37. The packaging method of claim 32, wherein the step of speeding
up the binding of the first annular glue wall is achieved using
radiation.
38. The packaging method of claim 23, wherein the second annular
glue wall is composed of a thermal plastic resin.
39. The packaging method of claim 23, wherein the second annular
glue wall is formed on the top surface of the first electrode by
printing.
40. The packaging method of claim 39, wherein the printing method
in the step of coating a first annular glue wall comprises: fixing
the second electrode on a printing tool; and applying half-tone
printing on the top surface of the second electrode.
41. The packaging method of claim 40, wherein the printing tool has
a container whose size and depth are approximately the same of
those of the second electrode so as to accommodate the second
electrode.
42. The packaging method of claim 41, wherein the bottom of the
container has a vacuum hole to suck and hold the second
electrode.
43. The packaging method of claim 23, wherein the step of coating a
second annular glue wall is formed using a glue supplier.
44. The packaging method of claim 23, wherein the second annular
glue wall is formed by immersing and coating.
45. The packaging method of claim 23, wherein the second annular
glue wall is formed by spraying and coating.
46. The packaging method of claim 23, wherein the step of coating a
second annular glue wall further contains the step of speeding up
the binding of the second annular glue wall.
47. The packaging method of claim 46, wherein the step of speeding
up the binding of the second annular glue wall is achieved by
heating.
48. The packaging method of claim 47, wherein the heating is done
using hot air.
49. The packaging method of claim 47, wherein the heating is done
using infrared light.
50. The packaging method of claim 46, wherein the step of speeding
up the binding of the second annular glue wall is achieved using
ultraviolet light.
51. The packaging method of claim 46, wherein the step of speeding
up the binding of the second annular glue wall is achieved using
radiation.
52. The packaging method of claim 23, wherein the step of filling
in an electrolyte solution further comprises the step of disposing
a separation plate on the top surface of the second electrode.
53. The packaging method of claim 52, wherein the separation plate
is porous and acid-resistant.
54. The packaging method of claim 52, wherein the separation plate
is a glass fiber plate.
55. The packaging method of claim 23, wherein the step of reflowing
uses a heat source to heat the first annular glue wall and the
second annular glue wall.
56. The packaging method of claim 55, wherein the step of reflowing
uses ultrasonic waves to heat the first annular glue wall and the
second annular glue wall.
57. The packaging method of claim 55, wherein the step of reflowing
uses hot air to heat the first annular glue wall and the second
annular glue wall.
58. The packaging method of claim 55, wherein the step of reflowing
uses infrared light to heat the first annular glue wall and the
second annular glue wall.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to an energy storage device
packaging method and, in particular, to a packaging method for
electric power storage units of an ultracapacitor energy storage
device.
[0003] 2. Related Art
[0004] A battery is a power device that converts energy of a
certain form directly into electrical power without going through
an intermediate mechanical conversion process. A capacitor is an
electronic device that stores charges. In general, batteries can
store a large amount of energy but have a lower output power, while
capacitors store little energy but can have a high output power.
Therefore, batteries are considered as an electrical power storage
device and capacitors are power storage devices. They are used by
human beings in various applications.
[0005] With the arrival of the 3C (computer, communications, and
consuming electronics) era, light, thin, short and small electronic
products with multiple functions and high efficiency are more and
more popular in our daily lives. Such products include notebook
computers, mobile phones, walkmans, etc. To make electronic
products portable and good for long term uses, a sufficient
portable power supply becomes the key problem. Conventional
combinations of batteries and capacitors obviously cannot satisfy
modern uses. A new energy storage device, the ultracapacitor, has
thus been invented.
[0006] Conventional capacitors use an insulating material or a
dielectric sandwiched between two conductors to achieve the
isolation effect. The capacitance is produced by separating
opposite charges on the conductor surfaces.
[0007] The electrochemical double layer (EDL) adopted in
ultracapacitor energy storage devices does not have an insulating
material to establish a dielectric layer. The charging and energy
storage occurs at the interface of the EDL. The ultracapacitor can
achieve an energy density and a power density far higher than the
conventional capacitor technology can. In comparison with
conventional batteries, ultracapacitors can release more than 100
times of power and store over 20 times of electrical energy.
[0008] Currently, ultracapacitor energy storage devices have gone
from the experimental phase into a few commercialized applications.
The product applications also gradually move from defensive
satellites and military uses to products in vehicle,
mechanical-electrical and communication electronics industries.
[0009] Please refer to FIGS. 1A and 1B for the structure and the
fabrication method of a conventional ultracapacitor energy storage
device. The method proposed in the U.S. Pat. Nos. 5,384,685,
5,464,453, 5,711,988, 5,800,857, and 5,821,033 is to dispose two
gaskets 12 between two electrodes 11. A block 13 is sandwiched
between the two gaskets 12, forming a stack structure 10. The
gasket is formed by using a polymer gel to form a film and then
cutting off the shape needed. The large surface covering layer 16
of the inner surface of the electrode 11 can be formed with a
proper little bump 17 to help supporting and insulating the two
electrodes 11.
[0010] Afterwards, the two gaskets 12 are heated for reflowing so
as to bind the two electrodes 11 and the two gaskets 12 together,
forming an enclosed gap 15 in the stack structure 10.
[0011] After cooling to the room temperature, the block 13 is
withdrawn to form a refill port 14 on a side surface of the stack
structure 10. An electrolyte solution is filled into the gap 15
inside the stack structure 10 through the refill port 14. Finally,
the refill port 14 is closed to complete the packaging of an
electric power storage unit.
[0012] However, the above packaging method has to form a gasket by
making a film from polymer gel and cutting the shape needed in
order to make the stack structure and refill port of the electric
power storage unit before putting in the electrolyte solution and
enclosing the refill port. The process is too complicated and not
suitable for mass production. Therefore, it is desirable to have a
new packaging method that solves the above problems.
SUMMARY OF THE INVENTION
[0013] In view of the foregoing, the invention provides a packaging
method for electric power storage units of an ultracapacitor energy
storage device that has a simplified procedure and is suitable for
mass production.
[0014] The disclosed packaging method directly fills in an
electrolyte solution during the electrode stacking process,
omitting the steps of scraping electrode sides, making polymer gel
films, cutting the shape needed, and forming and enclosing a refill
port. Therefore, it largely simplifies the process, increases the
production efficiency and lowers the cost.
[0015] The packaging method includes the following steps:
[0016] Coating a glue wall: coating an annular glue wall along the
upper surface border of a first electrode;
[0017] Filling in an electrolyte solution: filling an electrolyte
solution in the upper surface of the first electrode enclosed by
the annular glue wall;
[0018] Stacking electrodes: stacking a second electrode on the
first electrode;
[0019] Reflowing the glue wall: heating to reflow the annular glue
wall to bind the first electrode, the second electrode, and the
annular glue wall together, enclosing the electrolyte solution
between the first electrode and the second electrode.
[0020] The annular glue wall is composed of materials that are
acid-resistant and adhesive to the electrode. For example, the
material can be a thermal plastic resin that can be heated for
reflowing and congregation.
[0021] The lower surface of the second electrode can be formed with
a second annular glue wall, corresponding to the first annular glue
on the upper surface of the first electrode. The first annular glue
wall and the second annular glue wall can be heated and reflowed to
enclose the electrolyte solution so that the electric power storage
unit has a good closure.
[0022] In the step of coating a glue wall, hot air, infrared,
ultraviolet or radiation heating can speed up the congregation of
the annular glue walls. The heat source in the step of reflowing
the glue wall can be ultrasonic waves, hot air or infrared
light.
[0023] A separation plate can be installed on the upper surface of
the first electrode as the support structure of the electric power
storage unit, preventing a direct contact between the two
electrodes due to bending. The separation plate has to have the
properties of being porous, acid-resistant, and thin, such as a
glass fiber plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will become more fully understood from
the detailed description given hereinbelow illustration only, and
thus are not limitative of the present invention, and wherein:
[0025] FIG. 1A shows a three-dimensional perspective view of the
stack structure of the electric power storage units of an
ultracapacitor energy storage device in the prior art before
packaging;
[0026] FIG. 1B shows a stack structure of the electric power
storage units of an ultracapacitor energy storage device in the
prior art, whose side surface is formed with a refill port;
[0027] FIGS. 2A and 2B show a printing tool in an embodiment of the
invention, wherein FIG. 2B is a cross-sectional view of FIG. 2A
along the a-a' direction;
[0028] FIGS. 3A and 3B show an electrode formed on the printing
tool according to the embodiment of the invention, wherein FIG. 3B
is a cross-sectional view of FIG. 3A along the b-b' direction;
[0029] FIG. 4 illustrates that a resin glue is coated on the
electrode by half-tone printing in accordance with the embodiment
of the invention;
[0030] FIGS. 5A and 5B show an annular glue wall formed on the
electrode according to the embodiment of the invention, wherein
FIG. 5B is a cross-sectional view of FIG. 5A along the c-c'
direction;
[0031] FIG. 6 shows a three-dimensional perspective view of the
stack structure of an electric power storage unit on an ultrasonic
wave heating device;
[0032] FIG. 7 illustrates local heating on the annular glue wall of
the electric power storage unit stack structure using an ultrasonic
wave heating device according to the embodiment of the invention;
and
[0033] FIG. 8 shows a schematic cross-sectional view of the
packaged electric power storage unit after the reflow of the
annular glue walls according to the embodiment of the
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] A preferred embodiment of the packaging method for electric
power storage units of an ultracapacitor energy storage device is
shown in FIGS. 2A and 2B. First, a printing tool 20 is provided.
The printing tool 20 includes a top surface 21 and a container 22.
The bottom of the container 22 is formed with a vacuum hole 23
which provides vacuum suction.
[0035] Afterwards, as shown in FIGS. 3A and 3B, a first electrode
30 is disposed in the container 22 of the printing tool 20. The
first electrode 30 can be a thin square electrode with a thickness
of several mils (I mil=0.00254 cm). The length of its sides is
preferably several to tens of centimeters. Nevertheless, its shape
and size are not limited to the above ones.
[0036] The shape, size and depth of the container 22 is designed to
exactly accommodate the first electrode 30 so that the top surface
31 of the first electrode 30 is roughly as high as the top surface
21 of the printing tool 20.
[0037] After the first electrode 30 is put into the container 22,
the vacuum hole 23 provides a vacuum suction to hold the first
electrode 30 firmly inside the container 22 for subsequent printing
processes.
[0038] As shown in FIG. 4, a patternized half-tone plate 40
prepared in advance and a scraper 41 are provided to coat resin 42
on the top surface 31 of the electrode 30. The resin is preferably
a thermal plastic resin that is acid-resistant, adhesive to the
electrode, stable and has a good closure property in the
temperature range of -50.degree. C. to 75.degree. C. The resin 42
can be heated to a high temperature, such as 150.degree. C., so as
to be reflown into a liquid or semi-solid state for
congregation.
[0039] As shown in FIGS. 5A and 5B, the border on the top surface
31 of the first electrode 30 is formed with a first annular glue
wall 32 with a height of several mils.
[0040] With reference to FIG. 6, the first electrode 30 formed with
the first annular glue wall 32 is disposed in an ultrasonic tool
45. An electrolyte solution 33 is filled into the top surface of
the electrode 30 enclosed by the first annular glue wall 32. A
second electrode 35 is then stacked onto the first electrode 30.
Usually, the second electrode 35 has the same structure and size as
the first electrode 30. Preferably, the bottom surface of the
second electrode 35 that faces the first electrode 30 is formed
with a second annular glue wall 36 corresponding to the first
annular glue wall 32. The formation method for the second annular
glue wall 36 can be the same as that for the first annular glue
wall 32, i.e., by printing. Before stacking the second electrode
35, it is preferably to dispose a separation plate 34 on the top
surface 31 of the first electrode 30.
[0041] The separation plate 34 is used as a support structure
between the two electrodes 30, 35, preventing the electrodes 30, 35
from direct contact due to bending. The separation plate 34 has to
have such properties as being thin, porous and acid-resistant. It
can be a glass fiber plate.
[0042] 5 As shown in FIG. 7, a heating device is employed to heat
the first annular glue wall 32 and the second annular glue wall 36.
When the temperatures of the first annular glue wall 32 and the
second annular glue wall 36 are raised to a certain temperature,
they are reflown as shown in FIG. 8 so that the first electrode 30,
the second electrode 35, and the reflown annular glue wall 37 are
tightly bound together. The electrolyte solution 33 is then
enclosed between the first electrode 30 and the second electrode
35. Once the annular glue wall 37 cools down and cures, the
packaging of the electric power storage units of an ultracapacitor
energy storage device is then completed. The heating device 46 can
use ultrasonic waves, hot air, or infrared light.
[0043] Although the invention has been described with reference to
specific embodiments, this description is not meant to be construed
in a limiting sense. Various modifications of the disclosed
embodiments, as well as alternative embodiments, will be apparent
to persons skilled in the art. For example, the annular glue wall
can be made of other proper materials. The method for forming the
annular glue walls is not limited to half-tone printing but can be
formed by coating. Furthermore, besides local heating using
ultrasonic waves, the reflow of the annular glue walls can use
other methods. It is, therefore, contemplated that the appended
claims will cover all modifications that fall within the true scope
of the invention.
* * * * *