Abstract:
An electrolyte capacitor includes an anode, a cathode, and an electrolytic solution provided between the anode and the cathode. The anode may be a niobium porous sintered body with an oxide film formed as a dielectric layer on a surface thereof. The cathode allows an electric double layer at an interface with the electrolytic solution. The electrolyte capacitor has a large capacitance and increased voltage.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to an electric double layer capacitor and aggregation thereof.  
         [0003]     2. Description of the Related Art  
         [0004]     Capacitors are utilized in backup power supplies and auxiliary power supplies for portable electronic equipment including cell phones, rechargeable devices with solar batteries, and even motor power supplies or regenerative energy devices for so-called hybrid cars. In particular, electric double layer capacitors are suited for use in applications where large capacities are required.  
         [0005]      FIG. 15  shows one example of a conventional electric double layer capacitor. This electric double layer capacitor X includes an anode  91  and a cathode  92  having distribution electrodes  91   a ,  92   a  made from activated carbon, respectively. A partition wall  93  and an electrolytic solution  94  are arranged between the distribution electrodes  91   a ,  92   a . In the electric double layer capacitor X, so-called electric double layers are generated at interfaces between the electrolytic solution  94  and the distribution electrodes  91   a ,  92   a , on which positive and negative ions are distributed across the interfaces. The electric double layer is used for electric storage. Due to its relatively large electrostatic capacity, the electric double layer capacitor X is suitable for use in the above-mentioned power supply and storage applications.  
         [0006]     Recently, however, development of new capacitor applications has started in which capacitors with a relatively large capacity of about 100 μF to 10 F are installed into card-type devices, for example. Although high in capacitance, the electric double layer capacitor X has a structure sealed entirely by a metal cylinder can and does not represent a remarkable improvement in decreased size. Meanwhile, solid electrolytic capacitors are often used in applications requiring miniaturization. These solid electrolytic capacitors, however, do not lend themselves to an increased capacity. Accordingly, there are needs for capacitors that are compact, thin, and suitable for uses in which relatively large capacitances are required.  
         [0007]     Another related electric double layer capacitor is disclosed in Japanese Unexamined Patent Publication No. 2003-92234 (see  FIG. 1 ).  
       SUMMARY OF THE INVENTION  
       [0008]     In order to overcome the problems described above, preferred embodiments of the present invention provide an electrolytic capacitor that can be made smaller and thinner and has a relatively large capacitance.  
         [0009]     An electric double layer capacitor according to a first preferred embodiment of the present invention includes a pair of electrodes each including a carbon layer and disposed opposite to each other, a partition wall separating the pair of electrodes from each other, and an electrolytic solution intervening between the pair of electrodes, wherein the carbon layer has a thickness of about 6 μm or less.  
         [0010]     According to such a configuration, a current path becomes shorter between the electrodes and the electrolytic solution. The shorter the current path is, the smaller the electric double layer capacitor&#39;s ESR can be made, thereby reducing electric loss. Lowered ESR is convenient for quick discharge of electric energy stored in the electric double layer capacitor. Further, the thinner the carbon layer becomes, the more advantageously the electric double layer can be reduced in thickness.  
         [0011]     According to another preferred embodiment of the present invention, the electric double layer capacitor has a thickness of about 1,000 μm or less in the direction in which the pair of electrodes and the partition wall are layered. According to such a configuration, the electric double layer capacitor can be installed into thin electronic equipment such as a card-type device, for example.  
         [0012]     An electric double layer capacitor according to a second preferred embodiment of the present invention includes a pair of electrodes each including a carbon layer and disposed opposite to each other, a partition wall separating the pair of electrodes from each other, and an electrolytic solution intervening between the pair of electrodes, wherein the thickness in the direction in which the pair of electrodes and the partition wall are layered is about 1/50 or less of its width in the direction perpendicular to the direction of the layering.  
         [0013]     According to such a configuration, this preferred embodiment is suitable for installation into card-type devices or the like. It can also enhance the electric double layer capacitor&#39;s flexibility.  
         [0014]     An electric double layer capacitor according to a third preferred embodiment of the present invention includes a pair of electrodes each including a carbon layer and placed opposite to each other, a partition wall separating the pair of electrodes from each other, and an electrolytic solution intervening between the pair of electrodes, wherein the electric double layer capacitor can be bent due to its flexibility.  
         [0015]     According to such a configuration, this preferred embodiment can be installed into electric equipment having a flexible structure. More specifically, if a user uses the above-mentioned electric equipment in such a manner that it is bent or folded, the electric double layer capacitor can appropriately follow the bends or folds.  
         [0016]     In a preferred embodiment of the present invention, the withstand voltage of the electric double layer capacitor is about 1.2V or more.  
         [0017]     In another preferred embodiment of the present invention, the operating temperature limit of the electric double layer capacitor is about 100° C. or more.  
         [0018]     In another preferred embodiment of the present invention, the preferred embodiment described above further includes a pair of external electrodes each conductive to the above-mentioned pair of electrodes, and has a high-resistance portion which is arranged between at least one of the pair of electrodes and the external electrodes conductive thereto and is smaller in cross-sectional area than the one electrode and the external electrodes. According to such a configuration, this accomplishes a so-called fuse capability with which, when an excessive current passes through the high-resistance part, the high-resistance portion melts and thus cuts off the current due to Joule heating. Consequently, the high-resistance portion is suitable for protecting the electric double layer capacitor and electric equipment in which the same is installed.  
         [0019]     In another preferred embodiment of the present invention, the high-resistance portion includes wires.  
         [0020]     An aggregation of electric double layer capacitors according to a fourth preferred embodiment of the present invention includes a plurality of electric double layer capacitors provided by any one of the first to third preferred embodiments of the present invention.  
         [0021]     In another preferred embodiment of the present invention, the plurality of electric double layer capacitors are connected to one another in series.  
         [0022]     In another preferred embodiment of the present invention, the plurality of electric double layer capacitors are connected to one another in parallel.  
         [0023]     Other features, elements, processes, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]      FIG. 1  is an overall perspective view showing one example of an electric double layer capacitor according to a preferred embodiment of the present invention.  
         [0025]      FIG. 2  is an exploded perspective view of main components showing one example of an electric double layer capacitor according to a preferred embodiment of the present invention.  
         [0026]      FIG. 3  is a cross-sectional view of  FIG. 1  taken along the line III-III.  
         [0027]      FIG. 4  is an enlarged cross-sectional view of main components showing one example of an electric double layer capacitor according to a preferred embodiment of the present invention.  
         [0028]      FIG. 5  is an overall perspective view showing a bending state of one example of an electric double layer capacitor according to a preferred embodiment of the present invention.  
         [0029]      FIG. 6  is an overall perspective view of a partial cross section showing one example of a card-type device using the electric double layer capacitor shown in  FIG. 1 .  
         [0030]      FIG. 7  is a perspective view showing a process of attaching protective plates to an aluminum frame in one example of a manufacturing method of the electric double layer capacitor shown in  FIG. 1 .  
         [0031]      FIG. 8  is a perspective view showing a process of forming collector electrodes in one example of a manufacturing method of the electric double layer capacitor shown in  FIG. 1 .  
         [0032]      FIG. 9  is a perspective view showing a process of applying an electrolytic solution in one example of a manufacturing method of the electric double layer capacitor shown in  FIG. 1 .  
         [0033]      FIG. 10  is a perspective view showing a process of attaching a porous frame in one example of a manufacturing method of the electric double layer capacitor shown in  FIG. 1 .  
         [0034]      FIG. 11  is a perspective view showing a process of attaching an aluminum frame in one example of a manufacturing method of the electric double layer capacitor shown in  FIG. 1 .  
         [0035]      FIG. 12  is a perspective view showing a process of attaching protective plates in one example of a manufacturing method of the electric double layer capacitor shown in  FIG. 1 .  
         [0036]      FIG. 13  is a perspective view of a partial cross section showing one example of an electric double layer capacitor according to a preferred embodiment of the present invention.  
         [0037]      FIG. 14  is a perspective view of a partial cross section showing another example of an electric double layer capacitor according to a preferred embodiment of the present invention.  
         [0038]      FIG. 15  is a cross-sectional view showing one example of a conventional electric double layer capacitor. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0039]     Preferred embodiments of the present invention will be described specifically with reference to the drawings as below.  
         [0040]      FIG. 1  to  FIG. 5  show one example of an electric double layer capacitor according to a preferred embodiment of the present invention. The electric double layer capacitor A includes a pair of electrodes  1 A,  1 B, a partition wall  2 , an electrolytic solution  3 , a resin package  4 , a pair of external connecting terminals  5 A,  5 B, and high-resistance portions  6 A,  6 B.  FIG. 2  is an exploded perspective view of the electric double layer capacitor A with the electrolytic solution  3  and the resin package  4  omitted.  FIG. 4  is a partial enlarged view of  FIG. 3 .  FIG. 5  illustrates the electric double layer capacitor A in a bending state.  
         [0041]     The pair of electrodes  1 A,  1 B are arranged separated from and opposite to each other, as shown in  FIG. 3 . In using the electric double layer capacitor A, either one of the pair of electrodes  1 A,  1 B may be an anode and the other the cathode. As shown in  FIG. 2  and  FIG. 4 , the pair of electrodes  1 A,  1 B are configured to include collector electrodes  10 A,  10 B, distribution electrodes  11 A,  11 B, and protective sheets  12 A,  12 B, respectively.  
         [0042]     The collector electrodes  10 A,  10 B are defined by approximately square main bodies and extending portions  10 Aa,  10 Ba extending from the main bodies. The collector electrodes  10 A,  10 B are preferably aluminum plates, for example, and are preferably about 12 μm to about 50 μm in thickness, and are about 20 μm thick in this preferred embodiment. The main bodies are on the order of about 5 mm per side. The external connecting terminals  5 A,  5 B are coupled to the extending portions  10 Aa,  10 Ba through the high-resistance portions  6 A,  6 B.  
         [0043]     The distribution electrodes  11 A,  11 B are preferably formed by kneading fine particles of activated carbon with a binder, for example, and cover the main bodies of the collector electrodes  10 A,  10 B. The distribution electrodes  11 A,  11 B correspond to the carbon layers referred to in the preferred embodiments of the present invention. Further, so-called CARBON NANOBLACK™, for example, may be added in order to enhance conductivity between the activated carbon particles. The activated carbon particles are on the order of about 2 μm in average particle diameter, have microscopic asperities on their surfaces, and are relatively large in their surface areas per unit volume. The distribution electrodes  11 A,  11 B have a thickness on the order of about 6 μm.  
         [0044]     The protective plates  12 A,  12 B are for protecting the collector electrodes  10 A,  10 B and the distribution electrodes  11 A,  11 B, and are composed of polyimide resin, for example. Polyimide resin provides excellent electric isolation and flame resistance, and has a high degree of flexibility. The protective plates  12 A,  12 B are preferably about 30 μm in thickness.  
         [0045]     The partition wall  2  prevents the pair of electrodes  1 A,  1 B from contacting with and conducting to each other. The partition wall  2  also has the function of allowing the electrolytic solution  3  to pass through it such that the electrolytic solution  3  intervenes between the pair of electrodes  1 A,  1 B, and is defined by a porous body of polyolefin, for example. The partition wall  2  is of an approximately square of about 5.5 mm per side, and its thickness is preferably on the order of about 15 μm to about 20 μm and is about 20 μm in this preferred embodiment. The material of the partition wall  2  is not limited to a porous body of polyolefin, and may be any other suitable porous insulating material.  
         [0046]     The partition wall  2  and the distribution electrodes  11 A,  11 B are impregnated with the electrolytic solution  3  which intervenes between the pair of electrodes  1 A,  1 B. As the electrolytic solution  3 , for example, an ion liquid such as TEMA (tetraethylmethylammonium) of about 2 mg may be used. Accordingly, with its withstand voltage of about 3V, the electrolytic solution  3  will not deteriorate even if heated to the order of about 300° C. When a voltage is applied to the interfaces between the distribution electrodes  11 A,  11 B and the electrolytic solution  3 , charged ions fixed to the surfaces of the distribution electrodes  11 A,  11 B and ions within the electrolytic solution  3  in contact with the surfaces of the distribution electrodes  11 A,  11 B are distributed across the interfaces, thereby forming so-called electric double layers. The distance between positive and negative ions corresponds to the size of one molecule or so in the electric double layers. Thus, electric storage in the electric double layers has the characteristic that the electrostatic capacitance per unit area is relatively large.  
         [0047]     The external connecting terminals  5 A,  5 B are for connecting the electric double layer capacitor A to electronic equipment or the like (not shown), and are defined by substantially rectangular aluminum plates, for example. The high-resistance portions  6 A,  6 B intervene between the external connecting terminals  5 A,  5 B and the extending portions  10 Aa,  10 Ba, respectively.  
         [0048]     The high-resistance portions  6 A,  6 B are smaller in cross-sectional area than the extending portions  10 Aa,  10 Ba and the external connecting terminal  5 A,  5 B, and are defined by wires having a diameter of about 50 μm, for example. The high-resistance portions  6 A,  6 B serve as so-called fuses that melt due to Joule heating when an excessive current flows into the pair of electrodes  1 A,  1 B from the external connecting terminals  5 A,  5 B.  
         [0049]     The resin package  4  is for protecting the pair of electrodes  1 A,  1 B. The resin package  4  is composed of epoxy resin, for example, and is about 50 μm in thickness. The resin package  4  also prevents the electrolytic solution  3  from flowing outward or evaporating. A preferred material of the resin package  4  provides excellent insulation and flexibility and, accordingly, may be any material providing these properties. The resin package  4  is formed with a pair of openings  4   a . The pair of openings  4   a  is for exposing the pair of external connecting terminals  5 A,  5 B.  
         [0050]     The electric double layer capacitor A configured as described above has a thickness on the order of about 100 μm in the vertical direction as shown in  FIG. 3 . In addition, the electric double layer capacitor A has a capacitance of about 100 F.  
         [0051]     Further, as shown in  FIG. 5 , when the electric double layer capacitor A is supported at both ends thereof and provided with a force, the electric double layer A bends due to its overall deflection. In this preferred embodiment, a bending angle θ may be about 15 degrees to about 45 degrees.  
         [0052]     Next, a description will be provided as to one example of a manufacturing method of the electrolytic capacitor A.  
         [0053]     First, as shown in  FIG. 7 , an aluminum frame  10 A′ is prepared. The aluminum frame  10 A′ is a cutout of aluminum foil that is about 20 μm thick. A plurality of collector electrodes  10 A are arranged within the aluminum frame  10 A′. Protective plates  12 A are attached to the aluminum frame  10 A′ at the lower sides of portions as shown in  FIG. 7  which define individual collector electrodes  10 A. The protective plates  12 A are preferably composed of polyimide resin and have a thickness on the order of about 30 μm, for example.  
         [0054]     Next, as shown in  FIG. 8 , distribution electrodes  11 A are formed. The formation of the distribution electrodes  11 A is carried out by applying porous carbon to the aluminum frame  10 A′ at the upper sides of portions as shown in  FIG. 8  which define collector electrodes  10 A. The porous carbon in this preferred embodiment is a paste mixed with fine particles of activated carbon of about 2 μm in average particle diameter, for example. The thickness of the application of the porous carbon is preferably about 6 μm.  
         [0055]     After the forming of the distribution electrodes  11 A, the electrolytic solution  3  is applied as shown in  FIG. 9 . The application of the electrolytic solution  3  is carried out by dropping an ion liquid such as TEMA of about 2 mg to the distribution electrodes  11 A with the use of a dropper Sp, for example.  
         [0056]     Then, as shown in  FIG. 10 , a porous body frame  2 ′ is attached to the aluminum frame  10 A′ on which the distribution electrodes  11 A are formed. The porous frame  2 ′ is preferably composed of a porous body of polyolefin, for example, and has a thickness on the order of about 20 μm. A plurality of partition walls  2  are formed from the porous frame  2 ′.  
         [0057]     After attaching the porous frame  2 ′, as shown in  FIG. 11 , the aluminum frames  10 B′ are attached to the upper side of the porous frame  2 ′ as further shown in  FIG. 11 . The aluminum frame  10 B′ is a frame of aluminum from which a plurality of collector electrodes  10 B can be formed. The aluminum frame  10 B′ has distribution electrodes  11 B formed thereon. The formation of the distribution electrodes  11 B is the same as that of the distribution electrodes  11 A.  
         [0058]     Then, as shown in  FIG. 12 , protective plates  12 B are attached to the aluminum flame  10 B′ at the portions which define the collector electrodes  10 B. The material and dimensions of the protective plates  12 B are the same as those of the protective plates  12 A.  
         [0059]     After that, pieces of the layered collector electrodes  10 A,  10 B, distribution electrodes  11 A,  11 B, partition walls  2 , and protective plates  12 A,  12 B are cut out from the structure in the state shown in  FIG. 12 . Each of the cut-out pieces is connected with the high-resistance portions  6 A,  6 B and the external connecting terminals  5 A,  5 B shown in  FIG. 2  to form the resin package  4  shown in  FIG. 3 . Through the above described process, the electrolytic capacitor A shown in  FIG. 1  can be manufactured.  
         [0060]     Next, the action of the electrolytic capacitor A will be described.  
         [0061]     According to this preferred embodiment, the electric double layer capacitor A can be made thinner. In particular, a thickness of about 6 μm of the distribution electrodes  11 A,  11 B as carbon layers would be advantageous in order to provide a finished electric double layer capacitor A having a thickness of about 100 μm. This thickness reduction allows the electric double layer capacitor A to be installed in a card-type device B as shown in  FIG. 6 , for example. The card-type device B is equipped with electronic components such as infrared-emitting devices, for example, and has a thickness of about 1 mm. The electric double layer capacitor A is as thin as about 100 μm, and thus is suitable for use in supporting power supply to the electronic components in the card-type device B.  
         [0062]     Further, the electric double layer capacitor A has a flat shape about 100 μm thick and about 5 mm wide. It offers a high degree of flexibility with which it can be bent with its ends supported at an angle of about 15 degrees to about 45 degrees. Accordingly, when the electric double layer capacitor A is installed in the card-type device B, if the card-type device B itself has a compliant structure that can be freely bent by a user, the electric double layer capacitor A has the ability to follow the bends.  
         [0063]     The thinner the distribution electrodes  11 A,  11 B are, the less the resistance of the electric double layer capacitor A can be achieved (reduced ESR). In this preferred embodiment, the distribution electrodes  11 A,  11 B with a thickness of about 6 μm allows the ESR of the electric double layer capacitor A to be about 1 mΩ or lower.  
         [0064]     The provision of the electrolytic solution  3  composed of an ion liquid achieves a withstand voltage of about 3V. This is because, if the electric double layer capacitor A is to be used in a power supply application, for example, the limitation for the operating voltage of the electronic equipment to be supplied with power is relaxed. Moreover, in addition to the case with this preferred embodiment, if an organic electrolyte such as PC (propylene carbonate) is used as the electrolytic solution  3 , the withstand voltage can be about 2V. Further, if a water solution such as sulfuric acid is used as the electrolytic solution  3 , the withstand voltage can be about 1.2V.  
         [0065]     Reducing the ESR and raising the withstand voltage result in an improvement in power density. The power density is expressed as V 2 / 4 R and is an indicator meaning that the higher the value, the more quickly power can be supplied. Here, V is withstand voltage and R is ESR. According to this preferred embodiment, both a raised withstand voltage and reduced ESR are possible as stated above, which is suitable for increasing power density. The electric double layer capacitor A is provided for support of power supply to electronic components which operate at a high power in a short period of time.  
         [0066]     The electric double layer capacitor A can operate properly even at relatively high temperatures on the order of about 300° C. Therefore, it can be installed in electronic equipment used in environments at high ambient temperatures. Further, there is a low possibility that the electric double layer capacitor A is damaged or broken even if it generates internal heat during its use.  
         [0067]     The high-resistance portions  6 A,  6 B serve as so-called fuses, which make it possible to prevent an excessive current from flowing into the pair of electrodes  1 A,  1 B, thereby avoiding damaging or breaking of the electric double layer capacitor A. Further, the high-resistance portions  6 A,  6 B also act as fuses even if electric energy accumulated in the electric double layer capacitor A has been discharged to the outside due to the occurrence of a short-current. This properly avoids damage to the electronic equipment having the electric double layer capacitor.  
         [0068]      FIG. 13  shows one example of an aggregation of electric double layer capacitors according to a preferred embodiment of the present invention. An aggregation C of this preferred embodiment includes three electric double layer capacitors A and wires  7 A,  7 B and  7 C, and is installed in the card-type device B.  
         [0069]     The electric double layer capacitor A is identical to the above-described electric double layer capacitor A. The wire  7 A is connected to a positive electrode in the electric circuit of the card-type device B. The wire  7 B is connected to the negative electrode in the electric circuit of the card-type device B. The wire  7 C connects the external connecting terminals  5 A,  5 B of the adjacent electric double layer capacitors A. Consequently, the three electric double layer capacitors A are connected to one another in series through the wires  7 A,  7 B and  7 C.  
         [0070]     According to this preferred embodiment, it is easy to increase a withstand voltage of the aggregation C. Therefore, in the card-type device B, appropriate power supply can be carried out to the electronic components requiring higher-voltage power.  
         [0071]      FIG. 14  shows another example of an aggregation of electric double layer capacitors according to a preferred embodiment of the present invention. An aggregation C of this preferred embodiment includes three electric double layer capacitors A and wires  7 A,  7 B. In this preferred embodiment, the wire  7 A connects external connecting terminals  5 A of the three electric double layer capacitors A to one another. The wire  7 B connects external connecting terminals  5 B of the three electric double layer capacitors A to one another. With this, the three electric double layer capacitors A are connected in parallel to one another.  
         [0072]     According to this preferred embodiment, it is easy to increase the electrostatic capacitance of the aggregation C. Therefore, in the card-type device B, appropriate power supply can be carried out to the electronic components requiring larger-current power.  
         [0073]     An electric double layer capacitor and an aggregation of electrical double layer capacitors according to the present invention are not limited to the above described preferred embodiments. Specific configurations of an electric double layer capacitor and individual portions of an aggregation of electric double layer capacitors can be changed in design in a variety of manners.  
         [0074]     While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.