JP2009016787A - Electric double layer capacitor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric double layer capacitor with a large capacitance, which prevents internal short circuit and the peeling-off of an electrode material with the elapse of time regardless of compactness and is easily manufactured. <P>SOLUTION: In the electronic double layer capacitor 100, a plate-like first polymeric sheet 9 having insulation, a first plate-like current collector 1b brought into contact with the polymeric sheet 9, a first plate-like polarizable electrode 2b conductively brought into contact with or bonded to the polymeric sheet 9, a plate-like separator 3 conductively brought into contact with the first current collector 1b and impregnated with an electrolytic solution with cation and anion melted therein, a second plate-like polarizable electrode 2a conductively brought into contact with the separator 3, a second plate-like current collector 1a conductively brought into contact with or bonded to the second polarizable electrode 2a, and a plate-like polymeric cover 6 brought into contact with the second current collector 1a and having insulation are stacked. A plurality of posts 5 are formed integrally on the top surface of the polymeric sheet 9, and top ends of the plurality of posts 5 are bonded to and melted into the polymeric cover 6. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an electric double layer capacitor, and more particularly to an electric double layer capacitor that enables a large capacity.

An electric double layer capacitor (hereinafter, sometimes simply referred to as “capacitor”) is a capacitor having a large Farad order capacitance using an electric double layer generated at a polarizable electrode and an electrolyte interface.
Since (a) charging / discharging is a physical adsorption / desorption phenomenon of electrolyte ions to / from the electrode surface, deterioration due to charging / discharging is extremely small as compared with a secondary battery using a chemical reaction. (Ii) Larger capacitance can be obtained as the area capable of adsorbing ions per unit volume of the electrode is larger. (Iii) The charging / discharging time can be made much faster than a normal secondary battery. Etc.
However, since the conventional electric double layer capacitor has been developed for an auxiliary power supply, the idea for realizing a large capacitance has been lost.

  A typical cross-sectional structure of a conventional electric double layer capacitor includes a separator impregnated with an electrolysis solution, a pair of polarizable electrodes holding the separator, a pair of current collectors connected to each of the polarizable electrodes, Are laminated in a sandwich shape, and the laminate (hereinafter sometimes referred to as “capacitor element”) is liquid-tightly sealed in a container. At this time, the electrolytic solution is a solution in which cations and anions are dissolved, and a polarizable electrode formed of activated carbon is electrically connected to a current collector formed of a highly conductive material such as platinum or aluminum by a conductive adhesive or the like. Connected. In addition, external connection leads for electrical connection with the outside have entered the container in a liquid-tight manner and are connected to the current collector (see, for example, Patent Document 1).

Japanese Patent Laying-Open No. 2005-32938 (page 4-5, FIG. 2)

  However, in the invention disclosed in Patent Document 1, the separator is a thin plate, and the container in which the capacitor element is accommodated is configured by combining a pair of rectangular parallelepiped blocks each having a rectangular recess. Therefore, when trying to obtain a large-capacity large capacitor, there were the following problems. For this reason, in the invention disclosed in Patent Document 1, although a small capacitor can be made, a capacitor having a large capacitance such as a power storage device for solar cell power generation or an electric vehicle has a large area and a thin capacitor element. It was difficult to provide by.

(A) Since the capacitor element is accommodated in the rectangular recess, the capacitor element may move in the recess. For this reason, when the capacitor element has a large area and is arranged substantially vertically, the capacitor element moves downward, resulting in a decrease in adhesion (such as peeling) between members constituting the capacitor element and a container for storing the capacitor element. As a result, there is a possibility that the initial design capacitance may not be guaranteed.
(B) On the other hand, in order to prevent peeling of members constituting the capacitor element, deformation of a container for storing the member, etc., the bottom part (same as the ceiling part) forming the rectangular depression is not thickened. The volume of the rectangular parallelepiped block for holding the whole is overwhelmingly larger than the volume of the capacitor element that functions as a capacitor, which goes against the downsizing of the capacitor (downsizing and weight reduction).
In addition, if the pair of rectangular parallelepiped blocks that have become large are to be held firmly, it is necessary to tighten them with large fixing bolts / nuts, and this goes against the downsizing of the capacitor (downsizing and weight reduction).

(C) Also, a separator that has been sufficiently impregnated with an electrolyte solution, a pair of polarizable electrodes that have been sufficiently impregnated with an electrolyte solution, and a pair of current collectors joined to each of the polarizable electrodes are laminated. Then, it is difficult to manufacture a capacitor by sealing together because the electrolyte easily leaks.
(D) In addition, the electrical connection in a wide area guaranteed at the time of manufacture is sufficient due to the decrease in the adhesion between the members constituting the capacitor element that occurs during repeated charge and discharge (such as peeling of the electrode material). There was a risk that it could not be guaranteed.

  The present invention solves the above-mentioned problem, and prevents the movement of the capacitor element and the lowering of the adhesion between the members constituting the capacitor element, and is a compact electric double layer having a large area and a large capacitance. An object is to provide a capacitor.

(1) The electric double layer capacitor according to the present invention is
A sheet-like first support having insulating properties;
A sheet-like first current collector in contact with the first support;
A sheet-like first polarizable electrode electrically connected to the first current collector;
A plate-like separator that is in contact with the first polarizable electrode and impregnated with an electrolytic solution in which cations and anions are melted;
A sheet-like second polarizable electrode in contact with the separator;
A sheet-like second current collector electrically connected to the second polarizable electrode;
A sheet-like second support having insulating properties in contact with the second current collector;
Are stacked,
The first current collector, the first polarizable electrode, the separator, the second polarizable electrode, and the second current collector surround an outer periphery thereof, and the first Liquid-tightly sealed by the support and the second support,
A first external connection body electrically connected to the first current collector;
A second external connection body electrically connected to the second current collector;
An electric double layer capacitor having
A plurality of through-holes joined to both the first support and the second support and formed in the first current collector; and a plurality of through-holes formed in the first polarizable electrode; Insulating through the plurality of through holes formed in the separator, the plurality of through holes formed in the second polarizable electrode, and the plurality of through holes formed in the second current collector It has a plurality of pile bodies to comprise.

(2) In (1), the first support body, the bank body, and the pile body are integrally formed,
The second support body integrally has a bank covering body that surrounds the outer periphery of the bank body,
An end portion of the bank covering member is joined to the first support member.

(3) Moreover, in said (1), the said pile body is a pipe body,
The first support body, the bank body, and the pile body are integrally formed,
The second support body integrally includes a bank covering body that surrounds the outer periphery of the bank body, and a first support cover body that surrounds the outer surface of the first support body,
A part of said 2nd support body fills the inside of the said pile body, It is characterized by the above-mentioned.

  (4) In any one of the above (1) to (3), the second support body enters at least a gap between the through hole formed in the second current collector and the pile body. It is characterized by having a body integrally.

Since the electric double layer capacitor according to the present invention is as described above, the following effects can be obtained.
(I) A first current collector in which a plurality of pile bodies that are joined to both of the first support body and the second support body that are disposed opposite to each other and are connected to each other are stacked, and the first polarizability The pile body passes through the through holes formed in each of the electrode, the separator, the second polarizable electrode, and the second current collector (hereinafter collectively referred to as “c”). It functions as a “rivet” that maintains the shape of the capacitor element. Therefore, since the self-shape maintaining structure is formed, a large-capacity electric double layer capacitor having a large area can be obtained while being compact including the sheet-like first support and the second support. .
Further, since the capacitor element is sealed in a liquid-tight manner, there is no risk of liquid leakage. If the bank body is formed of a material having gas permeability, even if a gas is generated inside, the gas can be dispersed outside the capacitor element.
In the present invention, the sheet form does not limit the degree of thickness or rigidity (or flexibility), and includes, for example, a film material such as a film, a thin plate material, or a plate material having a predetermined thickness. .

(Ii) That is, even if the capacitor element has a large area, since the capacitor element is “pinned” at a plurality of locations, it does not move in one direction.
(Iii) Since the distance between the first support and the second support is maintained at a plurality of locations, the capacitor can be obtained by holding the capacitor element uniformly between the first support and the second support. The adhesion between members constituting the element is uniformly maintained over a wide range, and peeling or the like is prevented, so that the performance is sufficiently guaranteed even when used for a long period of time.

(Iv) Furthermore, since the capacitor element is housed in a recess formed by the bank body surrounding the outer periphery and the first support body, the capacitor element (particularly, the separator) is impregnated with an electrolyte in such a state. This makes it possible to prevent the electrolyte from leaking and facilitate manufacture. In addition, if the bank body is made of a gas-permeable material in addition to liquid-tightness, even if gas is generated inside, it is possible to disperse the gas outside the capacitor element. Become.
(V) Furthermore, since the levee body integrally joined to the second support body surrounds the outer periphery of the dam body and its end part is joined to the first support body, the capacitor element is In addition, the dam is double surrounded by the embankment and the electrolyte does not leak.

(Vi) Furthermore, since a part of the second support body is filled inside the pile body which is a tubular body, the adhesiveness (degree of integration) between the pile body and the second support body increases, and the second support body Since a part of the body is directly bonded (integrated) to the first support body, the function as the rivet of the pile body is guaranteed, and a more rigid self-form maintaining structure is formed.
(Vii) Further, since the second support body integrally includes a gap intruder that has entered at least a gap between the through hole formed in the second current collector and the pile body, the gap intruder is formed with the through hole. Since the outer periphery of the pile body is surrounded by the gap intruder and the inner periphery of the through hole formed in the second current collector surrounds the gap intruder, the gap intruder (first 2 (same as the support) and adhesion (degree of integration) is increased. Therefore, the function is guaranteed as the rivet of the pile body, and a more robust self-form maintaining structure is formed. At this time, a larger penetration depth of the gap intruder into the gap is suitable for improving the adhesiveness, and a part of the gap intruder may be directly bonded to the first support. .

[Embodiment 1]
FIG. 1 is a side sectional view schematically showing an electric double layer capacitor according to Embodiment 1 of the present invention. In FIG. 1, for convenience of explanation, the left-right direction in the figure is referred to as “width direction” or “horizontal direction”, and the up-down direction in the figure is referred to as “thickness direction” or “height direction”. Further, the size in the width direction (hereinafter referred to as “width”) and the size in the thickness direction (hereinafter referred to as “thickness” or “height”) of each component member are not limited. The magnitude relationship between the thicknesses (heights) may be reversed from that shown in the figure.

(Capacitor element)
In FIG. 1, an electric double layer capacitor (hereinafter referred to as “capacitor”) 100 corresponds to a sheet-like first support (hereinafter referred to as “polymer sheet”) 9 having insulating properties and a polymer sheet 9. The sheet-shaped first current collector 1b in contact with the sheet-shaped first polarizable electrode 2b electrically connected to the first current collector 1b (same for energization), and the first polarizable electrode 2b The plate-shaped separator 3 impregnated with the electrolyte solution in which the cation and the anion are melted, and the sheet-shaped second polarizable electrode 2a in contact with the separator 3, and the second polarizable electrode 2a are electrically contacted. A connected sheet-like second current collector 1a and a sheet-like second support body (hereinafter referred to as “polymer cover”) 6 having insulating properties in contact with the second current collector 1a are laminated. Has been.
For convenience of the following description, a stack of the first current collector 1b, the first polarizable electrode 2b, the separator 3, the second polarizable electrode 2a, and the second current collector 1a is used. This is referred to as “capacitor element 99”. Further, when explaining common contents, “first and second” for modifying the name and subscripts “a and b” for the symbols may be omitted.

(Sealed container)
A bank body (hereinafter referred to as “bank”) 11 is formed along the outer periphery of the polymer sheet 9, and the upper end of the bank 11 is bonded and fused to the polymer cover 6. Therefore, the polymer sheet 9, the bank 11, and the polymer cover 6 form a sealed container 98 having liquid tightness.
Also, a first external connection body (hereinafter referred to as “first external connection lead”) 10b connected to the first current collector 1b and a second external connection body (hereinafter referred to as “first external connection lead”) connected to the second current collector 1a. 10a (referred to as “second external connection lead”) penetrates the bank 11 in a liquid-tight manner. Therefore, the capacitor element 99 is liquid-tightly sealed in the sealed container 98.

(Tsutsumi)
The bank 11 may be formed integrally with the polymer sheet 9 in advance, or may be formed separately on the polymer sheet 9 by seal printing or the like.
Further, even if the first external connection lead 10b penetrates a through-hole formed in the bank 11 after the bank 11 is formed in the polymer sheet 9, the first external connection lead 10b is formed before the bank 11 is formed. It may be formed on the polymer sheet 9 by vapor deposition or the like. In the latter case, the bank 11 is provided on the first external connection lead 10b.

And since the liquid-tight recessed part is formed by the polymer sheet 9 and the bank 11 integrally formed in the polymer sheet 9, the separator 3 is accommodated in the recessed part, and this is impregnated with the electrolytic solution. By doing so, it is possible to easily impregnate a sufficient electrolytic solution without leaking the electrolytic solution to the outside.
In addition, the bank 11 forms a self-form maintaining structure in cooperation with the function of preventing the electrolyte from leaking to the outside as described above and the pile 5 described later. The bank 11 may be integrally formed with the polymer sheet 9 or may be separately manufactured and bonded to the polymer sheet 9.

(Electrode material sheet)
The first current collector 1b and the first polarizable electrode 2b are electrically connected (for example, bonded by a conductive adhesive) to form a first electrode material sheet 8b. The first electrode material sheet 8b includes a pile 5 is provided with a plurality of first sheet holes 7b having the same arrangement. Similarly, the second current collector 1a and the second polarizable electrode 2a are electrically connected to form a second electrode material sheet 8a, and the second electrode material sheet 8a has the same arrangement as the arrangement of the piles 5. A plurality of second sheet holes 7a are provided. The separator 3 is also provided with a plurality of separator holes 4 having the same arrangement as that of the piles 5.

(Self-form maintenance structure)
A plurality of pile bodies (hereinafter referred to as “pile”) 5 are integrally formed on the upper surface of the polymer sheet 9, and the upper ends of the plurality of piles 5 are bonded (melt-bonded) to the polymer cover 6. At this time, the pile 5 is set so as to penetrate the first sheet hole 7b, the separator hole 4, and the second sheet hole 7a. For this reason, since the plurality of piles 5 function as rivets that maintain the form between the polymer sheet 9 and the polymer cover 6, the sealed container 98 is entirely fixed by the bank 11 and the plurality of piles 5. "Self-form maintenance structure" is realized.
Therefore, even if the capacitor element 99 has a large area (the same as a large width) and the sealed container 98 is flattened, the capacitor element 99 is “pinned” at a plurality of locations, and thus moves in one direction. There is nothing to do.
Moreover, since the space | interval of the polymer sheet 9 and the polymer cover 6 is maintained in several places and a mutually parallel plane is maintained, if the capacitor element 99 is held uniformly beforehand, the member which comprises the capacitor element 99 The adhesion between each other is maintained uniformly over a wide range, and peeling or the like is prevented, so that the performance can be sufficiently guaranteed even after long-term use. In addition, this invention does not limit the quantity and shape of the pile 5.

(Materials of components)
The shape and material of the members constituting the present invention are not limited as long as they exhibit predetermined functions (liquid tightness, adhesiveness, etc.). Typical examples are shown below.
Separator 3 uses a nonwoven fabric such as polycarbonate.
A thin sheet made of stainless steel, aluminum, tantalum, titanium, or the like is used for the first current collector 1b and the second current collector 1a.
The first polarizable electrode 2b and the second polarizable electrode 2a are activated carbon, a conductive agent, a binder, etc., and are formed in a sheet shape.

A polymer resin having a melting point higher than that of the polymer cover 6 is used for the polymer sheet 9 (a plurality of piles 5 are formed). For example, when polyethylene or polypropylene is used for the polymer cover 6, polycarbonate or the like is used for the polymer sheet 9. Both are formed in a plate shape having a predetermined thickness and are bonded (melted and fixed) to each other to form the self-form maintaining structure.
In the present invention, the melting temperature of the polymer cover 6 (second support) is not limited to that lower than the melting temperature of the polymer sheet 9 (first support), and is substantially the same or slightly higher. It may be temperature. In short, the polymer cover 6 can be applied in a melted state, covers the upper surface of the second polarizable electrode 2a in a liquid-tight manner, and adheres (melts and adheres) to the top of the pile 5 and the bank 11. That's fine. Therefore, instead of the thermoplastic polymer resin, a polymer resin that is liquid at room temperature and is cured by heating, or a polymer resin that is cured by UV irradiation (UV curing) may be used.

(Electrolyte)
Propylene carbonate, ethylene carbonate, or the like is used as the electrolytic solution.
As the cation solute, a quaternary onium cation made of triethylmethylammonium ion or the like, or an alkali metal cation such as lithium ion or potassium ion is used. On the other hand, a salt in which anions such as BF4- and PF6- are combined is used as the solute for anions. Of course, a water-soluble electrolyte such as KOH can also be used. In this case, if the surface of the bank 11 and the surface of the pile 5 are subjected to water repellent treatment in advance, it is possible to prevent the electrolyte from leaking out and adversely affecting the assembly or subsequent processes.
The present invention is not limited to the one in which the electrolytic solution is impregnated only in the separator 3, and the total amount of the electrolytic solution in the capacitor 100 is impregnated in the first polarizable electrode 2 b or the second polarizable electrode 2 a in advance. The amount of impregnation may be increased. A solid electrolyte may be used.

(Pile)
FIG. 2 is a side sectional view schematically showing an example of a pile body in the electric double layer capacitor according to Embodiment 1 of the present invention.
In FIG. 2 (a), a weight-like pile 51 such as a cone or a polygonal pyramid is formed on the polymer sheet 9, and in FIG. 2 (b), a columnar pile 52 such as a cylinder or a polygonal column is formed on the polymer sheet. In FIG. 2C, a cylindrical pile 53 having a polygonal inner and outer shape is formed on the polymer sheet 9, but the present invention does not limit the shape.
In addition, the pile 51, the pile 52, and the pile 53 are not limited to those integrally formed with the polymer sheet 9, and may be joined after being manufactured separately from the polymer sheet 9. Further, either the pile 51, the pile 52, or the pile 53 may be mixed in the same polymer sheet 9.

(Production method)
3 and 4 are a side sectional view and a partial perspective view schematically illustrating the method for manufacturing the electric double layer capacitor according to the first embodiment of the present invention. In addition, the same code | symbol is attached | subjected to this same part as FIG. 1, and one part description is abbreviate | omitted. Hereinafter, description will be given based on FIG. 3 and FIG.

(1: Formation of electrode material sheet)
The first current collector 1b and the first polarizable electrode 2b are integrated to form the first electrode material sheet 8b. Similarly, the second current collector 1a and the second polarizable electrode 2a are integrated to form the second electrode material sheet 8a.

(2: Formation of sheet holes and separator holes)
When stacked, the first electrode material sheet 8b has a first sheet hole 7b and a second sheet corresponding to the position and size so that the plurality of piles 5 provided in the polymer sheet 9 penetrates. A second sheet hole 7 a is formed in the electrode material sheet 8 a and a separator hole 4 is formed in the separator 3.
At this time, the inner diameters of the first sheet hole 7 b, the second sheet hole 7 a, and the separator hole 4 are set to be slightly larger than the outer diameter of the pile 5. The hole diameter (outer diameter) of each hole is, for example, several mm, and is formed by punching or laser processing. Moreover, before the lamination | stacking process mentioned later, you may fully inject | pour beforehand the electrolyte solution (cation or anion) corresponding to each to the 1st polarizable electrode 2b and the 2nd polarizable electrode 2a.

(3: 1st lamination)
On the polymer sheet 9 on which the plurality of piles 5 are formed, the first electrode material sheet 8b to which the external connection leads 10 are connected is set by passing the pile 5 through the plurality of first sheet holes 7b. ).

(4: Formation of a bank)
The outer periphery of the first electrode material sheet 8 b is formed slightly smaller than the outer periphery of the polymer sheet 9. Therefore, the bank 11 is formed on the outer periphery of the polymer sheet 9. The bank 11 is made of an adhesive in which silicon-based spacers are dispersed, or a polymer that melts at a relatively low temperature and cures at room temperature. The bank 11 is formed by application using a dispenser or screen printing, and fixing by room temperature curing, UV curing, or the like. The height of the bank 11 is required to be at least a height at which the electrolyte used inside does not overflow to the outside.

(5: Second lamination)
Therefore, the separator 3 is set (placed) on the first electrode material sheet 8b surrounded by the formed bank 11 by penetrating the separator hole 4 along the pile 5.

(6: Impregnation with electrolyte)
Then, the separator 3 placed on the first electrode material sheet 8b is impregnated with an electrolytic solution in which cations and anions are sufficiently dissolved. The electrolytic solution is dripped onto the separator 3 with a dispenser or the like and sufficiently impregnated. In addition, after impregnating electrolyte solution beforehand, you may set a separator inside the bank 11.

(7: Third stack)
Further, the second electrode material sheet 8 a is set (placed) on the separator 3 with the plurality of piles 5 penetrating the second sheet hole 7. In addition, since the height of the pile 5 is slightly larger than the total thickness of the capacitor element 99, the upper end of the pile 5 protrudes slightly from the upper surface of the second electrode material sheet 8a. That is, when the polymer cover 6 described later is formed, the height of the pile 5 and the bank 11 is such that the upper portion of the pile 5 is sufficiently bonded and fused with the polymer cover 6 to sufficiently hold the internal capacitor element 99. Is determined in a timely manner.

(8: Air bleeding process)
The polymer sheet 9, the first electrode material sheet 8 b, the separator 3, and the second electrode material sheet 8 a laminated in a sandwich shape as described above are put in a weak vacuum apparatus, and the inside of the electrolyte solution and the electrode Air or water vapor remaining inside the material sheet is gradually removed.

(9: Formation of polymer cover)
After sufficiently removing internal air and water vapor, a polymer resin melted at a relatively low temperature is applied to the entire upper surface of the second electrode material sheet 8a to form the polymer cover 6. At this time, an appropriate pressure is selected for the capacitor element 99, and the polymer resin is applied to the entire surface of the electrode material sheet 8a while being pressurized (at this time, a heating roller may be used).
Therefore, the polymer cover 6 has a thickness of about 0.3 mm, for example, so that the upper ends of all the piles 5 that are exposed on the electrode material sheet 8a are sufficiently taken in. When the polymer applied in the heated and melted state is cured, the upper end of the bank 11 and the upper ends of all the piles 5 are bonded to the polymer cover 6.

  As a result, a self-maintaining structure is formed by the polymer sheet 9, the bank 11, the pile 5, and the polymer cover 6, and the members constituting the internal capacitor element 99 are in close contact with each other and fixed immovably. Thus, a compact electric double layer capacitor is formed. At this time, even in the case of the capacitor element 99 having a large area, the adhesion of each member constituting the capacitor element 99 is maintained by dispersing and arranging the piles 5 for each fixed area, and the capacitor element 99 becomes immovable. Since it is fixed, sufficient electrical connection can be maintained over a long period of time.

  Therefore, according to the present invention, a large-area, thin-thick, high-reliability, large-capacity electric double layer capacitor that has conventionally been difficult to manufacture can be compactly manufactured without depending on the capacitor material. The present invention is characterized in that the volume effective utilization rate is much higher than that of the conventional method, and because it has a large area and is thin, it is light in weight even when laminated, has a large capacity, and can be rapidly charged and discharged. Of course, this can be applied to newly developed capacitors with excellent capacitance characteristics.

The melting temperature of the polymer resin is suitably one that melts as low as possible so as not to adversely affect the internal electrolyte.
In addition, the polymer cover 6 is applied in such an amount that can surround the outer periphery of the bank 11 at the same time, and the polymer cover 6 is bonded and fused to surround the outer periphery of the bank 11 (hereinafter referred to as “bank cover”). ) 21 is formed, and the lower end of the bank cover 21 is bonded to the polymer sheet 9. Therefore, the capacitor element 99 is surrounded by the double bank (more precisely, the bank 11 and the bank cover 21), and the liquid tightness is improved. The formation of the bank cover 21 may be omitted.

Example 1
Next, an embodiment in which the electric double layer capacitor 100 is formed using a very general material will be described. In the description of the common contents, descriptions of “first and second” that modify the name and suffixes “a and b” of symbols are omitted.
An aluminum thin film 0.2 mm is used for the first current collector 1 b (positive electrode side), and a nickel thin film 0.2 mm is used for the second current collector 1 a (negative electrode side). For the polarizable electrode 2, activated carbon having a specific surface area of about 1000 m 2 / g is used.

And the electrode material sheet | seat 8 integrated the polar electrode 2 and the electrical power collector 1 by the press through the adhesive material which mixed the electrically conductive material like acetylene black, and a binder. The thickness of the electrode material sheet 8 was 0.4 mm, and the outer dimensions were 100 mm × 100 mm.
The electrode material sheet 8 is connected to an external connection lead 10 of Cu (including pure copper and copper alloy) having a width of 50 mm and a thickness of 0.3 mm.

  As the separator 3, polycarbonate having an area of 105 mm × 105 mm and a thickness of 0.2 mm was used. In addition, the electrode material sheet 8 and the separator 3 were each formed with a puncher so that the sheet hole 7 and the separator hole 4 having an outer diameter of 4 mm each having an area of 30 mm × 30 mm were in the same phase.

  The polymer sheet 9 has an area of 110 mm × 110 mm, uses 0.2 mm thick polycarbonate, and has one cylindrical pile 5 having an outer diameter of 4 mm and a height of 1.1 mm every 30 mm × 30 mm.

  The bank 11 was formed by using a dispenser to form a polymer solution for forming a polycarbonate base with a 0.8 mm diameter granular silica dispersed on the outermost periphery of the polymer sheet 9 to a width of about 4 mm and a height of about 1 mm.

  Quaternary onium cations such as R4N + and R4P +, and anions such as BF4- and PF6- were sufficiently dissolved in an electrolyte solution of propylene carbonate and ethylene carbonate. And after setting the separator 3 on the 1st electrode material sheet | seat 8b, the said electrolyte solution was dripped on the separator 3 using the dispenser, and was fully impregnated.

Further, by the above method, the second electrode material sheet 8a is laminated, the internal air and moisture of the capacitor element 99 are removed, and the entire surface of the polymer cover 6 made of polyethylene is covered (the entire surface of the bank 11 is covered and bonded to the polymer sheet 9). The levee cover 21 is formed).
Accordingly, a single unit electric double layer capacitor 100 of 110 mm × 110 mm thickness 1.5 mm, which was entirely covered and integrated by a thin polymer, was formed. The structure realized a capacity of 0.20 F / cm 2 per unit area and 20 F per unit.
In addition, the numerical value of each component in Example 1 is not optimized, and this invention is not limited to this. It will be changed depending on the material to be applied, the accuracy of each process, the product size to be designed, and the like.

[Embodiment 2]
FIG. 5 is a cross-sectional view in plan view schematically showing a bank constituting the electric double layer capacitor according to Embodiment 2 of the present invention. In FIG. 5, an electric double layer capacitor (not shown) according to the second embodiment is obtained by replacing the bank 11 of the electric double layer capacitor 100 shown in the first embodiment with a bank 211, In order to ensure the thickness, spacers 91 having a certain height are dispersed in the sealing material 92.

[Embodiment 3]
FIG. 6 is a partially enlarged sectional view in plan view schematically showing the electric double layer capacitor according to Embodiment 3 of the present invention. In addition, the same code | symbol is attached | subjected to the part which is the same as that of Embodiment 1, or an equivalent part, and a part of description is abbreviate | omitted.
In FIG. 6, an electric double layer capacitor 300 is an insulating (parallel arrangement) type multilayer stacked capacitor, and includes a first capacitor element 93 a, a second capacitor element 93 b, and a third capacitor element 93 c (hereinafter, referred to as “capacitor”). Are collectively referred to as “capacitor element 93”), being insulated by plate-like insulator 13ab and insulator 13bc. At this time, the capacitor element 93 is the same as the capacitor element 99 described above.

The second current collectors 1a of the capacitor elements 93 are collected inside the bank 11, and penetrate the bank 11 in a liquid-tight manner as second external connection leads 10a (not shown). Similarly, the first current collector 1b of each capacitor element 93 is gathered inside the bank 11, and penetrates the bank 11 in a liquid-tight manner as a first external connection lead 10b (not shown).
Therefore, the total area of the capacitor elements can be increased without increasing the area in plan view. At this time, since the pile 53 exerts the rivet effect, the capacitor element 93 is not deteriorated in adhesion (separation or the like), and the performance deterioration due to aging is prevented.
In addition, the manufacturing method of the electric double layer capacitor 300 is based on the capacitor 100.

Moreover, since the cylindrical pile 53 is formed in the polymer sheet 9, when the upper polymer cover 6 is formed, a polymer resin heated and melted in the pile 53 (hereinafter referred to as “intrusion into the pile”). 60) is full. Therefore, the polymer cover 6 is bonded to a wide range of the inner periphery together with the upper portion of the pile 53, and a part of the polymer cover 6 is directly bonded to the polymer sheet 9, so that a solid self-form maintaining structure is provided. Is formed.
Furthermore, the lower part of the bank cover 21 is extended, and a first support cover (hereinafter referred to as “seat cover”) 31 covering the outer surface of the polymer sheet 9 is formed. Therefore, the polymer sheet 9 and the polymer cover 6 are connected and fixed by the intruder 60 in the pile that has entered the pile 53, and the electric double layer capacitor 300 includes the polymer cover 6, the bank cover 21, and the sheet cover 31. Thus, the entire outer periphery is continuously surrounded and fixed.
Also in this case, the bank 11 has a function of preventing the electrolyte from leaking to the outside and a mechanism as a rivet, and its height is very important.

(Example 2)
Using the same material, a unit with a height of 2 mm is formed on a 300 mm x 300 mm electrode material sheet. When stacking up to a height of 100 mm, if 50 units are formed in one package, the storage capacity is 7500 F / package. It became. Of course, in this case as well, heat generation associated with charging / discharging does not become a problem. In addition, the numerical value of each component in Example 2 is not optimized, and this invention is not limited to this. It will be changed depending on the material to be applied, the accuracy of each process, the product size to be designed, and the like.

[Embodiment 4]
FIG. 7 is a partially enlarged sectional view in plan view schematically showing the electric double layer capacitor according to the fourth embodiment of the present invention. Note that the same or corresponding parts as those in Embodiment 3 (FIG. 6) are denoted by the same reference numerals, and description thereof is partially omitted.
In FIG. 7, an electric double layer capacitor 400 is a serially arranged multilayer multilayer capacitor, and is a capacitor unit layer 94 formed by laminating a first polarizable electrode 2b, a separator 3 and a second polarizable electrode 2a. Are stacked with the bipolar electrode (hypolar electrode) 14 removed.

That is, the first capacitor unit layer 94a, the bipolar electrode 14ab, the second capacitor unit layer 94b, the bipolar electrode 14bc, and the third capacitor unit layer 94c are sequentially stacked.
The second polarizable electrode 2a of the third capacitor unit layer 94c is supported in contact with the second current collector 1a, and is connected to the second external connection lead 10b. Similarly, the first polarizable electrode 2b of the first capacitor unit layer 94a is supported in contact with the first current collector 1b, and is connected to a first external connection lead 10b (not shown).

Therefore, a high voltage capacitor can be easily obtained simply by sequentially stacking the capacitor unit layers 94 by using a bipolar material instead of a mere collector electrode to stack the positive and negative electrodes. For example, when the capacitor unit layer 94 is one layer, the voltage of 1.5 V can be changed to 3 V or 6 V simply by stacking. At this time, since the pile 53 exhibits the rivet effect, the capacitor unit layer 94 And the bipolar electrode 14 are not deteriorated in adhesion (peeling or the like), and performance deterioration due to aging is prevented.

The material of the bipolar electrode 14 is not limited and, for example, graphite is used.
The manufacturing method of the electric double layer capacitor 400 is the same as that of the capacitor 100, and each separator 3 may be impregnated with an electrolytic solution separately, or after all the capacitor elements 93 are laminated, You may impregnate the electrolyte solution at once. In the latter case, the bipolar electrode 14 is porous and allows the electrolytic solution to pass (impregnate).

[Embodiment 5]
FIG. 8 is a side sectional view schematically showing the electric double layer capacitor according to the fifth embodiment of the present invention. The same parts as those in the first embodiment are denoted by the same reference numerals, and a part of the description is omitted.
In FIG. 8, an electric double layer capacitor (hereinafter referred to as “capacitor”) 500 is replaced with a polymer sheet 9 in place of the columnar pile 5 formed on the polymer sheet 9 of the capacitor 100 (Embodiment 1). A conical pile 51 is formed.
A part of the polymer cover 6 (a gap 77a between the pile 51 and the second sheet hole 7a, a gap 73 between the pile 51 and the separator 3, and a gap 77b between the pile 51 and the first sheet hole 7b ( (Hereinafter referred to as “gap intruder”) 61 has entered.

Therefore, the gap intruder 61 is bonded to a wide range of the outer surface of the pile 51. Further, the lower end of the gap intruder 61 is directly bonded to the polymer sheet 9. Therefore, the polymer cover 6 and the polymer sheet 9 are firmly joined to form a self-form maintaining structure.
In the present invention, a part of the polymer cover 6 may enter only the gap 77a, but as the penetration depth increases, the adhesion area between the gap intruder 61 and the outer surface of the pile 51 increases. Adhesion is more reliable.
Furthermore, it replaces with the pile 51 and installs the column-shaped pile 52 and the cylindrical pile 53 (refer FIG. 2), adjusts the internal diameter of the 2nd sheet | seat hole 7a, and the pile 52, the pile 53, and the 2nd sheet | seat. The gap intruder 61 may enter the gap with the hole 7a. Of course, you may make it penetrate | invade into the clearance gap between the separators 3 and the 1st sheet | seat hole 7b.
And the form of Embodiment 5 can be implemented also in Embodiment 3 and Embodiment 4.

  As described above, since the present invention is compact but has a large area and a large capacity, the present invention makes a tremendous contribution to the human society that is much like the conventional capacitor concept. For example, as an ideal energy source with no environmental damage such as fossil fuels and nuclear fuels, such as the use of full-scale electric vehicles in actual social life and the realization of a full-scale power supply system using solar cells. Can be widely used.

1 is a side sectional view schematically showing an electric double layer capacitor according to a first embodiment of the present invention. Sectional drawing of the side view which shows typically the example of the pile body in the electric double layer capacitor shown in FIG. Sectional drawing of the side view explaining the manufacturing method of the electrical double layer capacitor shown in FIG. FIG. 2 is a partial perspective view illustrating a method for manufacturing the electric double layer capacitor shown in FIG. 1. Sectional drawing of planar view which shows typically the bank which comprises the electric double layer capacitor which concerns on Embodiment 2 of this invention. The partial expanded sectional view of the side view which shows typically the electric double layer capacitor which concerns on Embodiment 3 of this invention. The partial expanded sectional view of the side view which shows typically the electric double layer capacitor which concerns on Embodiment 4 of this invention. Sectional drawing of the side view which shows typically the electric double layer capacitor which concerns on Embodiment 5 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Current collector 2 Polarized electrode 3 Separator 4 Separator hole 5 Pile 6 Polymer cover 7 Sheet hole 8 Electrode material sheet 9 Polymer sheet 10 External connection lead 11 Levee 13 Insulator 14 Bipolar electrode 21 Levee cover 31 Sheet cover 51 Pile 52 Pile 53 Pile 60 Penetration body in pile 61 Gap penetration body 73 Gap (pile and separator hole)
77 Clearance (pile and sheet hole)
91 Spacer 92 Sealing Material 93 Capacitor Element 94 Capacitor Unit Layer 98 Sealed Container 99 Capacitor Element 100 Electric Double Layer Capacitor (Embodiment 1)
211 Tsutsumi (Embodiment 2)
300 Electric double layer capacitor (Embodiment 3)
400 Electric Double Layer Capacitor (Embodiment 4)

Claims (4)

A sheet-like first support having insulating properties;
A sheet-like first current collector in contact with the first support;
A sheet-like first polarizable electrode electrically connected to the first current collector;
A plate-like separator that is in contact with the first polarizable electrode and impregnated with an electrolytic solution in which cations and anions are melted;
A sheet-like second polarizable electrode in contact with the separator;
A sheet-like second current collector electrically connected to the second polarizable electrode;
A sheet-like second support having insulating properties in contact with the second current collector;
Are stacked,
The first current collector, the first polarizable electrode, the separator, the second polarizable electrode, and the second current collector surround an outer periphery thereof, and the first Liquid-tightly sealed by the support and the second support,
A first external connection body electrically connected to the first current collector;
A second external connection body electrically connected to the second current collector;
An electric double layer capacitor having
A plurality of through-holes joined to both the first support and the second support and formed in the first current collector; and a plurality of through-holes formed in the first polarizable electrode; Insulating through the plurality of through holes formed in the separator, the plurality of through holes formed in the second polarizable electrode, and the plurality of through holes formed in the second current collector An electric double layer capacitor comprising a plurality of pile bodies provided. The first support body, the bank body, and the pile body are integrally formed,
The second support body integrally has a bank covering body that surrounds the outer periphery of the bank body,
The electric double layer capacitor according to claim 1, wherein an end portion of the levee is joined to the first support. The pile body is a pipe body,
The first support body, the bank body, and the pile body are integrally formed,
The second support body integrally includes a bank covering body that surrounds the outer periphery of the bank body, and a first support cover body that surrounds the outer surface of the first support body,
The electric double layer capacitor according to claim 1, wherein a part of the second support is filled in the pile body.   The said 2nd support body has a clearance gap intrusion body which penetrate | invaded into the clearance gap between the through-hole formed in the said 2nd electrical power collector and the said pile body integrally, The any one of Claim 1 thru | or 3 characterized by the above-mentioned. An electric double layer capacitor according to claim 1.

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