Electrochemical energy storage devices and manufacturing methods

1. An ultra-thin electrochemical energy storage device, comprising:

a pair of respective internal electrodes with electrolyte;

a separator layer between said respective electrodes;

a pair of respective current collectors, with one each of said current collectors respectively outside each of said electrodes; and

a case surrounding said current collectors, and having a respective pair of terminals connected respectively with said current collectors;

wherein the contents of said case have a thickness down to less than 0.5 millimeters; and

wherein said device has a resistivity of no more than about 1.5 Ω·cm 2 of electrode area.

2. An ultra-thin electrochemical energy storage device as in claim 1 , wherein said case has a moisture content of no more than about 10 ppm.

3. An ultra-thin electrochemical energy storage device as in claim 1 , wherein said electrolyte comprises an organic electrolyte.

4. An ultra-thin electrochemical energy storage device as in claim 1 , wherein said electrolyte includes at least some of propylene carbonate.

5. An ultra-thin electrochemical energy storage device as in claim 1 , wherein:

said device has a temperature operational range rating of −40° to 70° C.

6. An ultra-thin electrochemical energy storage device as in claim 1 , further comprising a plurality of said devices arranged as multiple cells positioned in a plurality of stacks configured in one of series or parallel connections, or combinations thereof.

7. An ultra-thin electrochemical energy storage device as in claim 1 , wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

8. An ultra-thin electrochemical energy storage device as in claim 1 , wherein:

said electrolyte comprises an organic electrolyte; and

said device comprises an electrochemical double layer (ECDL) capacitor having a capacitance density of at least about 10 Farads per cc of active electrode volume.

9. An ultra-thin electrochemical energy storage device as in claim 8 , wherein:

said electrolyte has a boiling point over 200° C.;

said case further includes thermally stable sealant materials; and

said capacitor has a temperature operational half-voltage range rating of up to 90° C.

10. An ultra-thin electrochemical energy storage device as in claim 8 , wherein:

said organic electrolyte includes at least some of propylene carbonate; and

said case has dimensions of about 50 mm long×40 mm wide×0.5 mm thick, and maintains dimensional stability at up to about 105° C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ.

11. An ultra-thin, ultra-low ESR supercapacitor, comprising:

a pair of respective internal electrodes with organic electrolyte;

an ultra-thin separator layer between said respective electrodes;

a pair of respective multi-layer current collectors, with one each of said current collectors respectively outside each of said electrodes; and

a case surrounding said current collectors, and having a respective pair of terminals connected respectively with said current collectors;

wherein the contents of said case have a thickness down to less than 0.5 millimeters, and a moisture content of no more than about 10 ppm, and

said supercapacitor has a resistivity of no more than about 1.5 Ω·cm 2 of electrode area, capacitance density of at least about 10 Farads per cc of active electrode volume, and a temperature operational range rating of −40° to 70° C.

12. A supercapacitor as in claim 11 , wherein said supercapacitor comprises a carbon double layer capacitor with a voltage rating of 4.2 volts, and a temperature operational half-voltage range rating of −40° to 90° C.

13. A supercapacitor as in claim 11 , wherein said organic electrolyte includes at least some of propylene carbonate.

14. A supercapacitor as in claim 13 , wherein said case has dimensions of about 50 mm long×40 mm wide×0.5 mm thick, and maintains dimensional stability at up to about 105° C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ.

15. A supercapacitor as in claim 11 , further comprising a plurality of said supercapacitors arranged as multiple cells positioned in a plurality of stacks.

16. A supercapacitor as in claim 15 , wherein said stacks of multiple cells are arranged in one of series or parallel connections, or combinations thereof.

17. A supercapacitor as in claim 11 , wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

18. A supercapacitor as in claim 11 , wherein:

said electrolyte has a boiling point over 200° C.;

said case further includes thermally stable sealant materials; and

said supercapacitor has a temperature operational half-voltage range rating of up to 90° C.

19. Methodology for manufacturing an ultra-thin electrochemical energy storage device, comprising:

providing a pair of respective internal electrodes with electrolyte, and with a separator layer between such respective electrodes;

providing a pair of respective current collectors, with one each of such current collectors respectively outside each of such electrodes; and

surrounding such current collectors with a case having a respective pair of terminals connected respectively with such current collectors;

wherein the contents of such case have a thickness down to less than 0.5 millimeters; and

wherein said device has a resistivity of no more than about 1.5 Ω·cm 2 of electrode area.

20. Methodology as in claim 19 , wherein said methodology is performed in a controlled environment having a moisture content of no more than about 10 ppm.

21. Methodology as in claim 19 , wherein said electrolyte comprises an organic electrolyte.

22. Methodology as in claim 19 , wherein said electrolyte includes at least some of propylene carbonate.

23. Methodology as in claim 19 , wherein:

said device has a temperature operational range rating of −40° to 70° C.

24. Methodology as in claim 19 , further comprising arranging a plurality of said devices as multiple cells positioned in a plurality of stacks configured in one of series or parallel connections, or combinations thereof, for selectively achieving desired capacitance and/or operational voltage levels.

25. Methodology as in claim 19 , wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

26. Methodology as in claim 19 , wherein:

said electrolyte comprises an organic electrolyte; and

said device comprises an electrochemical double layer (ECDL) capacitor having a capacitance density of at least about 10 Farads per cc of active electrode volume.

27. Methodology as in claim 26 , wherein:

said electrolyte has a boiling point over 200° C.;

said case further includes thermally stable sealant materials; and

said capacitor has a temperature operational half-voltage range rating of up to 90° C.

28. Methodology as in claim 26 , wherein:

said organic electrolyte includes at least some of propylene carbonate; and

said case has dimensions of about 50 mm long×40 mm wide×0.5 mm thick, and maintains dimensional stability at up to about 105° C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ.

29. Methodology for making an ultra-thin, ultra-low ESR supercapacitor, comprising:

providing a pair of respective internal electrodes with organic electrolyte, and with an ultra-thin separator layer between such respective electrodes;

providing a pair of respective multi-layer current collectors, with one each of such current collectors respectively outside each of such electrodes; and

surrounding such current collectors with a case having a respective pair of terminals connected respectively with such current collectors;

wherein the contents of said case have a thickness down to less than 0.5 millimeters, and said methodology is performed in a controlled environment having a moisture content of no more than about 10 ppm, and

said supercapacitor has a resistivity of no more than about 1.5 Ω·cm 2 of electrode area, capacitance density of at least about 10 Farads per cc of active electrode volume, and a temperature operational range rating of −40° to 70° C.

30. Methodology as in claim 29 , wherein said supercapacitor comprises a carbon double layer capacitor with a voltage rating of 4.2 volts, a temperature operational half-voltage range rating of −40° to 90° C.

31. Methodology as in claim 29 , wherein said organic electrolyte includes at least some of propylene carbonate.

32. Methodology as in claim 31 , wherein said case has dimensions of about 50 mm long×40 mm wide×0.5 mm thick, and maintains dimensional stability at up to about 105° C. storage temperature, while also maintaining very low ESR of down to about 150 mΩ.

33. Methodology as in claim 29 , further comprising a plurality of said supercapacitors arranged as multiple cells positioned in a plurality of stacks, for selectively achieving desired capacitance and/or operational voltage levels.

34. Methodology as in claim 33 , wherein said stacks of multiple cells are arranged in one of series or parallel connections, or combinations thereof, for achieving hybrid packs of a battery or batteries combined with a capacitor or capacitors in a single integrated product.

35. Methodology as in claim 29 , wherein:

said device includes a plurality of said pair of internal electrodes, separator layer, and said pair of current collectors surrounded by said case; and

said case has a thickness of from 0.5 millimeters to 5.0 millimeters.

36. Methodology as in claim 29 , wherein:

said electrolyte has a boiling point over 200° C.;

said case further includes thermally stable sealant materials; and

said supercapacitor has a temperature operational half-voltage range rating of up to 90° C.