Methods and apparatus for providing storage cell for energy storage device
An energy storage apparatus for mounting on a printed circuit board using a solder reflow process includes: a sealed housing body including a positive internal contact and a negative internal contact disposed within the body and in electrical communication with respective external contacts. An electric double layer capacitor energy storage cell is disposed within the body Methods of manufacture are disclosed.
1 . An energy storage device comprising:
an energy storage cell comprising:
an electrolyte;
a plurality of two-sided electrodes; and
a single separator; wherein the plurality of two-sided electrodes and the single separator are immersed in the electrolyte; wherein a first electrode of the plurality of electrodes is disposed onto one end of the single separator and wherein a second electrode of the plurality of electrodes is disposed onto an opposing end of the same single separator; and continuous strips of the two-sided electrodes are wound into a roll form and separated by the single separator forming a stack comprising a two-sided negative electrode and a two-sided positive electrode;
wherein the energy storage cell is wound into a roll, and each of the first electrodes and each of the second electrodes contact multiple electrically conductive tabs that extend beyond the energy storage cell and each of the conductive tabs are offset laterally sideways from each other to accommodate for an increasing radius of the energy storage cell in the roll;
wherein the multiple electrically conductive tabs collectively result in leaders aligned with electrical pads of a housing body; and
wherein the energy storage cell is an ultracapacitor capable of surviving reflow processing.
2 . The energy storage device of claim 1 , wherein the energy storage cell is disposed in a body that is fitted with a lid; wherein the body and the lid is configured for surface mounting on a printed circuit board with a solder reflow process.
3 . The energy storage device of claim 1 , wherein an interior of the lid and an interior of the body are protected with a protective layer.
4 . The energy storage device of claim 3 , wherein the protective layer comprises polytetrafluoroethylene or polyimide.
5 . The energy storage device of claim 1 , wherein a two-sided electrode of the plurality of two-sided electrodes comprises a current collector with energy storage media disposed on either side of the current collector.
6 . The energy storage device of claim 5 , wherein the current collector comprises aluminum and wherein the energy storage media comprises an active material.
7 . The energy storage device of claim 6 , wherein the active material is disposed on the current collector without the aid of binder.
8 . The energy storage device of claim 6 , wherein active material comprises activated carbon bound together by a matrix of carbon nanotubes.
9 . The energy storage device of claim 6 , wherein the active material comprises vertically aligned carbon nanotubes.
10 . The energy storage device of claim 1 , where the plurality of two-sided electrodes comprise a plurality of left-handed two-sided electrodes and a plurality of right handed two-sided electrodes.
11 . The energy storage device of claim 1 , wherein the single separator comprises polytetrafluoroethylene.
12 . The energy storage device of claim 1 , wherein the second electrode is oppositely disposed to the first electrode.
13 . A method comprising:
disposing in a body cavity of a body:
an energy storage cell comprising:
an electrolyte;
a plurality of two-sided electrodes; and
a single separator; wherein the plurality of two-sided electrodes and the single separator are immersed in the electrolyte; wherein a first electrode of the plurality of electrodes is disposed onto one end of the single separator and wherein a second electrode of the plurality of electrodes is disposed onto an opposing end of the same single separator; and continuous strips of the two-sided electrodes are wound into a roll form and separated by the single separator forming a stack comprising a two-sided negative electrode and a two-sided positive electrode, wherein the energy storage cell is wound into a roll;
wherein the method further comprises contacting each of the first electrodes and each of the second electrodes with multiple electrically conductive tabs that extend beyond the energy storage cell and laterally sideways offsetting the electrically conductive tabs from each other to accommodate for an increasing radius of the energy storage cell in the roll;
wherein the multiple electrically conductive tabs collectively result in leaders aligned with electrical pads of the body;
wherein the energy storage cell is an ultracapacitor capable of surviving reflow processing; and
disposing a lid onto the body cavity.
14 . The method of claim 13 , further comprising disposing on the body or the lid a printed circuit board.