CN112271081A - 卷绕式电容器 - Google Patents
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Abstract
本发明提供了一种卷绕式电容器,其包括由挠性多层带形成的卷(coil),以及位于卷的对接部的第一端接电极(第一接触层)和第二端接电极(第二接触层)。挠性多层带包含以下顺序的层:第一金属层、塑料层、第二金属层、储能材料层。第一金属层与第一端接电极(第一接触层)形成欧姆接触,第二金属层(第二接触层)与第二端接电极形成欧姆接触。
Description
本申请是申请号为201680046612.1、申请日为2016年6月24日、发明名称为“卷绕式电容器”的专利的分案申请。
背景技术
具有高体积能量密度、高工作温度、低等效串联电阻(ESR)和长寿命的电容器是用于脉冲电源、汽车和工业电子产品的关键组件。电容器中的电介质材料的物理特性是决定电容器性能的主要因素。因此,电容器中的电介质材料的一个或多个物理性质的改善能够导致电容器组件的相应性能的改善,通常导致电子系统或组装于其中的产品的性能和寿命增强。由于电容器电介质的改进能够直接影响产品尺寸、产品可靠性和产品效率,所以这种改进具有很高的价值。
电容器的电介质材料的某些改进可以被认为能够实现特定的技术应用。例如,具有高介电常数、高介电强度、低ESR和低介电损耗因数的电容器能够将高频或脉冲电源的应用减小到实用的尺寸。高温运行将大大简化下一代电动车。改进的电介质将使开关电源、功率调节器和滤波器的比功率和可靠性得到提高。提高能量密度将减少目前用于印刷电路板上的电容器器件的面积,减少用于油气井的功率调节系统、电源和井下工具的重量和尺寸。
为了在保持所有其他物理和电特性的同时减小电容器的尺寸,必须增加电容器的介电常数或绝缘击穿强度。两者都是通过开发具有高电压击穿强度、高介电常数和低ESR损耗的新型薄挠性电介质来实现的。某些应用还需要稳定的介电常数,在温度超过150摄氏度时寿命不会减少。
通常使用缠绕成圆柱形的金属化聚合物膜来制成高压非极性电容器。在传统的缠绕式电容器(wound capacitor)中,电介质材料通常是聚合物膜。常见的聚合物电介质材料包括聚碳酸酯、聚对苯二甲酸乙二醇酯(PET,也称为聚酯)、聚丙烯、聚苯乙烯和聚砜。基于聚合物电介质的箔电容器通常通过将聚合物和金属箔的交替片放置在叠层中并且将叠层卷成管状形状,或者在聚合物的一侧上沉积金属膜,然后将两个堆叠的金属化聚合物膜卷成管状形状。电线连接到每个金属箔。电介质材料以自支撑层的形式存在,其足够厚以维持必要的操作电压(通常至少3-6微米)。不幸的是,聚合物片材的厚度太大会降低能量储存密度。通常,由于聚合物材料的缺陷,这些电容器的介电常数会改变,并且在超过100-150℃的温度下寿命会缩短。或者,将涂覆有薄金属层(通常17-100纳米厚)的两个聚合物膜卷缠绕成管状以形成电容器。薄金属膜具有以下优点,即如果聚合物电介质在操作过程中破裂,则清除可能形成的任何短路。这能够延长电容器的使用寿命,并最大限度地减少电容器产生灾难性故障的可能性。因为薄膜的相对介电常数(也称为介电常数κ)相对较低,例如小于约5,因此常规的薄膜电容器不具有高能量密度。
在现有技术中,作为电容器的介电材料而公开了非结晶SiO2、HfO2、其它金属氧化物、非结晶氧化物和氮化物例如SiO2/Si3N4的叠层。在现有技术中还公开了包含两侧涂覆有薄金属层的绝缘聚合物膜的挠性衬底、以及在膜上沉积非结晶氧化物和氧化物/氮化物层以生产可卷成圆柱形状的材料的工艺。
在现有技术中,金属化膜电容器是公知的。这些电容器包括缠绕在一个芯上的两个紧密缠绕的薄片(sheet)。每个薄片包括电介质层和金属化层。金属化层不延伸到薄片的相对的端部而在每个薄片的相对侧上留下非金属化边缘。用导电金属喷涂由两个紧密卷绕的薄片形成的辊的端部,从而形成用于电容器的导电端子。以这种方式制造的电容器可以用于各种目的,这取决于诸如片材的类型、以及薄片的厚度和介电常数等因素。用于薄片的典型材料例如有定向聚丙烯或聚对苯二甲酸乙二醇酯。导电金属端子通常在真空镀膜机中形成,并且通常由铝、锌或其合金组成。
发明内容
本发明提供一种卷绕式电容器(coiled capacitor),其能够解决与某些储能器件相关的进一步增加储能体积和质量密度的问题,同时降低材料成本。
本发明的一个方面包括被设计得取得以下效果的材料的应用,即1)高介电常数,2)允许高电压的高介电强度(也称为击穿场强EBD),以及3)更少量的载体衬底。
在一个方面,本发明提供一种卷绕式电容器,其包括由挠性多层带(flexiblemultilayered tape)形成的卷盘(coil)、以及位于所述卷盘的对接部(butt)的第一端接电极(第一接触层)和第二端接电极(第二接触层)。挠性多层带包含以下顺序的层:第一金属层、塑料层、第二金属层、储能材料层。第一金属层与第一端接电极(第一接触层)形成欧姆接触,第二金属层(第二接触层)与第二端接电极形成欧姆接触。
交叉引用
在此通过参考同样地合并本说明书中提及的所有出版物、专利和专利申请,犹如每个单独的出版物、专利或专利申请被具体和单独地引用。
附图说明
图1a、1b和1c示意性地示出了在塑料层的顶面和底面上形成成组的金属条。
图2示出了在塑料层的一个金属化表面上形成储能材料层。
图3示出了在多层带上切割中间产品。
图4示出了多层带的缠绕。
图5示出了第一端接电极和第二端接电极的形成。
图6示出了基于第二实施例而在塑料层的顶面和底面上形成两个金属条。
图7示出了储能材料层的形成。
图8显示了多层带的缠绕。
图9示出了第一端接电极和第二端接电极的形成。
具体实施方式
在此说明和描述本发明的各种实施例,但对于本技术领域的技术人员来说,这些实施例当然只用于示例。在不脱离本发明的情况下,本技术领域的技术人员能够进行各种变形、改进和替换。应该理解为可以采用本发明所述的实施例的各种替代方案。
本发明提供一种卷绕式电容器。根据本发明的一个方面,卷绕式电容器还包括电介质芯,挠性多层带卷绕在该电介质芯上。储能材料的特征可以在于大于约100的介电常数κ和大于或等于约0.001伏(V)/纳米(nm)的击穿场强Ebd。介电常数κ可以大于或等于约100、200、300、400、500、1000、2000、3000、4000、5000、6000、7000、8000、9000、10000或100000。击穿场强可以大于约0.01V/nm、0.05V/nm、0.1V/nm、0.2V/nm、0.3V/nm、0.4V/nm、0.5V/nm、1V/nm或10V/nm。作为示例而非限制,储能材料的特征可以在于介于约100与约1000000之间的介电常数κ以及介于约0.01V/nm与约2.0V/nm之间的击穿场强Ebd。作为示例而非限制,储能材料可以包含萘嵌苯片段(rylene fragment)。根据本发明的另一个方面,萘嵌苯片段可以选自表1中给出的结构1-21。
表1.包含萘嵌苯片段的储能材料的实例:
在基于本发明的多个方面的卷绕式电容器的一个例子中,储能材料选自掺杂的低聚苯胺(doped oligoaniline)和对-低聚-亚苯基(p-oligo-phenylene)。在另一个卷绕式电容器的例子中,掺杂的低聚苯胺是在苯胺的苯环上具有SO3-基团或COO-基团的自掺杂低聚苯胺。在卷绕式电容器的另一个实施例中,掺杂的低聚苯胺是通过在氧化态下将有机结构-无机/有机酸与低聚苯胺混合而混合掺杂的,其中有机结构选自烷基、芳基及其聚合物,无机/有机酸选自SO3H、COOH、HCl、H2SO4、H3PO4、HBF4、HPF6、苯甲酸及其衍生物。根据本发明的又一个方面,储能材料可以包含可溶于有机溶剂中的聚合物材料。在本发明的又一个实施例中,储能材料包含可溶于有机溶剂中的具有选自表2中给出的结构22至27的结构的聚合物。
表2.包含可溶于有机溶剂的聚合物的储能材料的实例
其中每个R1和R2独立地选自烷基、芳基、取代的烷基和取代的芳基。在卷绕式电容器的另一个实施例中,储能材料包括在绝缘基体中分散有导电不等轴粒子的胶体复合物。在卷绕式电容器的又一个例子中,所述导电不等轴粒子包括导电低聚物。在卷绕式电容器的又一个例子中,所述绝缘基体的材料选自聚(丙烯酸)(PAA)、聚(N-乙烯基吡咯烷酮)(PVP)、聚(偏氟乙烯-六氟丙烯)[P(VDF-HFP)]、包括乙烯丙烯橡胶(EPR)和乙烯丙烯二烯单体(EPDM)在内的乙烯丙烯聚合物、以及诸如二甲基二氯硅氧烷、二甲基硅烷二醇和聚二甲基硅氧烷那样的硅橡胶(PDMSO)、聚苯乙烯磺酸(PSS)。在卷绕式电容器的一个实施例中,储能材料包含选自十二烷基苯磺酸盐(DBSA)、聚氧乙烯二醇烷基醚(polyoxyethyleneglycol alkyl ethers)、聚氧丙二醇烷基醚(polyoxypropylene glycol alkyl ethers)、聚氧乙烯二醇辛基苯酚醚(polyoxyethylene glycol octylphenol ethers)、聚氧乙烯乙二醇脱水山梨糖醇烷基酯(polyoxyethylene glycol sorbitan alkyl esters)、脱水山梨糖醇烷基酯(sorbitan alkyl esters)、十二烷基二甲基氧化胺(dobecyldimethylamineoxide)的表面活性剂。
在卷绕式电容器的另一个实施例中,储能材料包括陶瓷悬浮液、溅射薄膜和分子排序晶体(molecularly ordered crystal)。如本说明书所述,术语分子排序晶体是指通过级联结晶组装的膜或由包含溶致液晶(lyotropic liquid crystals)的溶液制成的膜。分子有序晶体的实例包括但不限于例如在2015年5月21日提交的美国专利申请号14/719072(代理人案卷号CSI-005)中描述的储能分子材料,其全部内容通过引用并入本文。作为举例而非限制,用超分子复合物(supramolecular complexes)通过胶体系统制备分子有序晶体的方法可以包括以下步骤:
-将胶体系统施加到衬底上。所述胶体系统通常具有触变性能,其通过保持分散相的预设温度和一定浓度而提供;
-对系统进行外部校准(external alignment),其可以利用机械因素或通过任何其他手段来进行,例如在正常或升高的温度下、有或没有额外的照明、磁场或光场(例如相干光伏效应)地施加外部电场;外部校准的程度应该足以向胶体系统的动力学单元赋予必要的取向,并形成作为结晶电介质层的晶格基底的结构;
-干燥除去溶剂而形成最终的分子排序晶体。
在卷绕式电容器的又一个例子中,所述塑料选自聚丙烯(PP)、聚对苯二甲酸乙二醇酯聚酯(PET)、聚苯硫醚(PPS)、聚萘二甲酸乙二醇酯(PEN)、聚碳酸酯(PP)、聚苯乙烯(PS)和聚四氟乙烯(PTFE)。在卷绕式电容器的又一个实施例中,所述塑料层的厚度不能小于2μm。在卷绕式电容器的又一个实施例中,所述塑料层的厚度在2.5μm到52μm之间变化。在卷绕式电容器的一个例子中,所述塑料层包含聚丙烯,并且所述塑料层的厚度等于12μm。在卷绕式电容器的另一个例子中,所述第一金属层和所述第二金属层的材料独立地选自Pt、Cu、Al、Ag、Au、Ni、Al:Ni以及泡沫金属。在卷绕式电容器的又一个例子中,所述第一和第二接触层的厚度独立地在10nm到1000nm之间变化。在卷绕式电容器的一个实施例中,所述第一和第二接触层的薄层电阻(sheet resistance)独立地不能小于0.1欧姆/平方。在卷绕式电容器的另一个例子中,所述第一和第二接触层的薄层电阻独立地在0.1欧姆/平方到2.5欧姆/平方之间变化。在卷绕式电容器的又一个例子中,泡沫金属的金属选自Al、Ni、Fe、Cu。在卷绕式电容器的一个例子中,泡沫金属的熔化温度为400℃~700℃的范围。在卷绕式电容器的另一个例子中,用于电极的泡沫金属中的金属含量为5重量%到30重量%。在卷绕式电容器的另一个例子中,泡沫金属是封闭“气泡”型,每单位金属含量具有最大的电导率。在卷绕式电容器的又一个例子中,“气泡”的大小为100nm至100000nm的范围。在卷绕式电容器的一个例子中,所述第一端接电极和第二端接电极的材料独立地选自Pt、Cu、Al、Ag和Au。在卷绕式电容器的另一个实施例中,所述第一金属层沉积在所述塑料层的第一表面的一部分上,并且该第一表面具有没有沉积金属的第一边缘部分,并且其中所述第二金属层沉积在所述塑料层的第二表面的一部分上,并且该第二表面具有第二边缘部分,该第二边缘部分没有沉积的金属并且位于所述塑料层的与所述第一边缘部分相对的边沿上。
根据本发明的其他方面,储能材料可以包括超分子或分子堆叠。可以通过自组装分子堆叠成棒状分子结构而形成这种超分子。这种结构的例子包括但不限于选自表1中给出的结构以及表3中给出的结构28-62的结构。
表3.储能材料中的超分子结构的其他例子
为了由这种超分子结构形成储能材料,可以利用超分子化学来修饰有机分子并且在液体中自组装以形成溶致液晶。将含有溶致液晶的液体涂布在衬底上,在涂布时使液晶校准。随着液体干燥,液晶随后结晶形成储能材料。
为了更容易理解本发明而参考以下实施例,这些实施例旨在说明本发明,但并不意在限制范围。
例子
例1
本例子示意性地描述了基于本发明的一个方面的用于制造卷绕式电容器的一系列技术操作。这个例子代表了所述卷绕式电容器的可能的制造方法之一。图1a、1b和1c示出了塑料层(4)的顶部(2,图1b)和底部(3,图1c)表面上的金属条(1)的形成。图1a示出位于顶面上的金属条相对于位于底面上的金属条的位移。在这个例子中,金属条的宽度可以在1厘米至100厘米的范围内变化。宽度并不限于指定的值范围。通常,针对每个应用而计算所需的宽度。各种因素都可能影响宽度的大小,例如卷尺寸、功率、能量等。对宽度的大的影响能够使所述卷绕式电容器的期望应用成为可能。金属条的厚度可以在0.01μm至1μm的范围内变化。条之间的距离可以在0.5毫米到3毫米之间变化。这个例子的关键特征是使用一个塑料层作为用于电容器中的所有层的承载衬底,这些层被涂覆在这个塑料层上或由该塑料层支撑。
金属条被形成在塑料层的相对表面上,使得在塑料层的每个表面上已经产生没有沉积金属的边缘部分,并且这些边缘部分位于塑料层的相对边沿上。接着的阶段是在图2所示的塑料层的金属化表面之一上形成储能材料层的形成步骤。该形成步骤包括两个步骤:第一步骤是施加储能材料的溶液的施加步骤,第二步骤包括干燥所施加的溶液以形成储能材料的固体层(5)的干燥步骤。储能材料层的厚度可以在0.5μm至50μm的范围内变化。因此在这个阶段形成了用于进一步形成卷绕式电容器的中间产品。然后,将中间产品切割到多层带上。图3示出了所得到的多层带的示意图。图3示出了第一金属层(6)沉积在塑料层(7)的第一表面的一部分上,并且该第一表面具有没有沉积金属的第一边缘(8),所述第二金属层(9)沉积在塑料层(7)的第二表面的一部分上,并且该第二表面具有第二边缘部分(10),所述第二边缘部分(10)没有沉积金属并且位于塑料层的与第一边缘部分相对的边沿上。另外进行多层带的缠绕(参见图4)。然后形成位于缠绕卷的对接部的第一端接电极(第一接触层)(11)和第二端接电极(第二接触层)(12)(见图5)。最后,通过在卷绕式电容器的第一和第二端接电极上施加精确校准的电压来完成愈合,从而任何存在的缺陷将被“烧掉”。
例2
本例子示意性地描述了用于制造卷绕式电容器的另一系列技术操作。图6示出了在塑料层(17)的顶部(15)和底部(16)的表面上形成两个金属条(13)和(14)。图6示出了位于顶面上的金属条相对于位于底面上的金属条侧向移位。因此,第一金属带(13)沉积在塑料层(15)的第一表面的一部分上,并且该第一表面具有没有沉积金属的第一边缘部分(18),并且其中第二金属带(14)沉积在塑料层(16)的第二表面的一部分上,并且该第二表面具有第二边缘部分(19),所述第二边缘部分(19)没有沉积金属并且位于塑料层的与第一边缘部分相对的边沿上。塑料层的厚度在2.5微米到52微米之间变化。金属条的宽度可以在1cm至100cm的范围内变化,并且其厚度可以在0.01μm至1μm的范围内变化。塑料层被用作电容器中的所有其他层的承载衬底,这些层被涂覆在该塑料层上或由该塑料层支撑。
接着的阶段是在图7所示的塑料层的金属化表面之一上形成储能材料层(20)的形成步骤。该形成步骤包括两个步骤:第一步骤是施加储能材料的溶液的施加步骤,第二步骤包括干燥以形成储能材料的固体层(20)的干燥步骤。储能材料层的厚度可以在0.5μm至50μm的范围内变化。进而将多层带卷绕成卷(参见图8)。然后形成位于卷的对接部的第一端接电极(第一接触层)(21)和第二端接电极(第二接触层)(22)(参见图9)。最后,通过在卷绕式电容器的第一和第二端接电极上施加精确校准的电压来完成愈合,从而任何存在的缺陷将被“烧掉”。
以上详细说明了本发明的优选实施例,但是也可以使用各种备选方案、改进和等价物。因此,以上说明并不限定本发明的范围,而是由权利要求及其等价物来确定。以上描述的无论是否优选的任何特征都可以与所描述的无论是否优选的任何其他特征相结合。在权利要求中,除非另有明确说明,不定冠词一个是指文章后面的一个或多个项的数量。正如此处所使用的,在替代元素的列表中,“或”字用于逻辑包含的含义,例如,除非明确说明,“X”或“Y”包括单独的X、单独的Y、或其两者X和Y,。列为备选方案的两个或多个元素可以组合在一起。权利要求并不限于包括装置加功能的限定,除非这种限定在一个给定权利要求中明确地使用了短语“装置”。
Claims (11)
2.根据权利要求1所述的卷绕式电容器,其特征在于,还包括电介质芯,所述挠性多层带卷绕在所述电介质芯上。
3.根据权利要求1所述的卷绕式电容器,其特征在于,所述储能材料包括陶瓷悬浮液、溅射薄膜或分子排序晶体。
4.根据权利要求1所述的卷绕式电容器,其特征在于,所述塑料选自聚丙烯(PP)、聚对苯二甲酸乙二醇酯聚酯(PET)、聚苯硫醚(PPS)、聚萘二甲酸乙二醇酯(PEN)、聚碳酸酯(PP)、聚苯乙烯(PS)和聚四氟乙烯(PTFE),并且所述塑料层的厚度不能小于2μm。
5.根据权利要求4所述的卷绕式电容器,其特征在于,所述塑料层包括聚丙烯或聚乙烯,并且所述塑料层的厚度等于12μm。
6.根据权利要求1所述的卷绕式电容器,其特征在于,所述第一金属层和所述第二金属层的材料独立地选自Pt、Fe、Cu、Al、Ag、Au、Ni、Al:Ni以及泡沫金属。
7.根据权利要求1所述的卷绕式电容器,其特征在于,所述第一端接电极和所述第二端接电极的厚度独立地在10nm到1000nm之间变化,并且所述第一端接电极和所述第二端接电极的薄层电阻独立地不能小于0.1欧姆/平方。
8.根据权利要求1所述的卷绕式电容器,其特征在于,所述第一或第二金属层是泡沫金属,并且所述泡沫金属的熔化温度在400℃-700℃的范围内。
9.根据权利要求1所述的卷绕式电容器,其特征在于,所述第一或第二金属层是泡沫金属,并且用于电极的所述泡沫金属中的金属含量为5重量%到至多30重量%。
10.根据权利要求1所述的卷绕式电容器,其特征在于,所述第一或第二金属层是泡沫金属,并且所述泡沫金属是封闭“气泡”型,每单位金属含量具有最大的电导率,并且其中所述泡沫金属中的“气泡”的大小在100nm至100000nm的范围内。
11.根据权利要求1所述的卷绕式电容器,其特征在于,所述第一金属层沉积在所述塑料层的第一表面的一部分上,并且所述第一表面具有没有沉积金属的第一边缘部分,并且所述第二金属层沉积在所述塑料层的第二表面的一部分上,并且该第二表面具有第二边缘部分,该第二边缘部分没有沉积金属并且位于所述塑料层的与所述第一边缘部分相对的边沿上。
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Application Number | Priority Date | Filing Date | Title |
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US14/752,600 US9941051B2 (en) | 2015-06-26 | 2015-06-26 | Coiled capacitor |
US14/752,600 | 2015-06-26 | ||
CN201680046612.1A CN108292563B (zh) | 2015-06-26 | 2016-06-24 | 卷绕式电容器 |
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CN108292563B (zh) | 2020-09-08 |
US9941051B2 (en) | 2018-04-10 |
US10672561B2 (en) | 2020-06-02 |
US20200251281A1 (en) | 2020-08-06 |
CA2990425A1 (en) | 2016-12-29 |
WO2016210349A1 (en) | 2016-12-29 |
CN108292563A (zh) | 2018-07-17 |
EP3314623A1 (en) | 2018-05-02 |
KR20180021069A (ko) | 2018-02-28 |
EP3314623A4 (en) | 2019-03-13 |
JP2018526815A (ja) | 2018-09-13 |
US20160379757A1 (en) | 2016-12-29 |
JP6762967B2 (ja) | 2020-09-30 |
US20180226193A1 (en) | 2018-08-09 |
US10854386B2 (en) | 2020-12-01 |
JP2020205445A (ja) | 2020-12-24 |
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