Asymmetric Electrode Termination Capacitor Design
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Solution Overview
Problem
Conventional electric double layer capacitors face challenges in further reducing size while maintaining capacitance and minimizing resistance, as equal protruding lengths of positive and negative electrode terminations lead to uneven stress distribution and increased risk of short-circuiting due to localized electric current concentration.
Innovation Solution
The capacitors are designed with asymmetric protruding lengths of bare portions without carbon-containing electrode layers, where one side bonded to the metal casing has a shorter protruding length than the other side bonded to the terminal plate, allowing for a reduced height and increased effective electrode surface area without altering the overall height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If equal protruding lengths are used for both positive and negative electrode terminations, then structural symmetry and ease of manufacture are improved, but element height cannot be reduced and effective electrode surface area is limited
Solution Approach 1:
The patent applies asymmetry by setting different protruding lengths for the positive and negative electrode terminations. Specifically, one termination has a protruding length of 0.5-2.0mm while the other has 2.0-5.0mm, creating an asymmetric structure that allows the element height to be reduced by the difference in protruding lengths while maintaining manufacturing feasibility
Solution Approach 2:
The patent applies local quality by differentiating the protruding lengths of specific electrode terminations based on their functional requirements. The termination with the shorter protruding length is optimized for one electrode while the other termination has a longer protruding length, allowing local optimization of the structure to reduce overall element height without compromising manufacturing
2Ease of manufacture
If equal protruding lengths are used for both electrode terminations, then manufacturing simplicity is improved, but capacitance is limited due to reduced effective electrode surface area
Solution Approach 1:
The asymmetric protruding length design allows one electrode termination to have optimal contact area with the collector while the other has reduced protrusion, thereby maximizing the effective electrode surface area available for capacitance without complicating the manufacturing process
Solution Approach 2:
The patent changes the geometric parameter of protruding length differently for each electrode termination, optimizing the effective surface area for capacitance storage. By setting specific ranges (0.5-2.0mm and 2.0-5.0mm), the design maximizes the active electrode area while maintaining manufacturing simplicity
3Volume of moving object
If asymmetric protruding lengths are used, then element height is reduced and effective electrode surface area is increased, but stress distribution becomes uneven
Solution Approach 1:
The patent optimizes the asymmetric protruding lengths within specific ranges (0.5-2.0mm and 2.0-5.0mm) to balance the reduction in element height with acceptable stress distribution. The parameters are carefully selected to minimize uneven stress while achieving compact dimensions
Solution Approach 2:
The design anticipates potential stress concentration issues by carefully selecting the protruding length differences within optimized ranges, effectively cushioning against excessive stress concentration before it occurs during assembly and operation
4Quantity of substance
If asymmetric protruding lengths are used, then effective electrode surface area is increased for higher capacitance, but manufacturing complexity increases
Solution Approach 1:
The asymmetric design is implemented in a way that maintains manufacturing simplicity by using standard fabrication processes. The different protruding lengths are achieved through conventional cutting and forming operations, avoiding the need for complex manufacturing equipment or multi-step processes
Solution Approach 2:
The patent applies local quality by differentiating only the protruding length parameter of the electrode terminations while keeping the rest of the structure and manufacturing process uniform. This localized differentiation maximizes effective surface area without significantly increasing overall manufacturing complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves an 8% increase in capacitance and an 8% decrease in resistance, enabling a more compact and efficient capacitor suitable for applications like hybrid vehicle power regeneration.
Implementation Method 1
a carbon-containing electrode layer formed thereon
Implementation Method 2
capacitors used for regeneration of power in a variety of electronic apparatuses, hybrid vehicles and the like and storage of power
Implementation Method 3
Negative electrode termination 11c of element 11 inserted in metal casing 12 is bonded both mechanically and electrically to an inner bottom surface of metal casing 12 by such means as laser welding
Data Source
AI summary
A capacitor for use in a hybrid vehicle and the like has a structure contrived to achieve reduction in size, increase in capacitance and decrease in resistance. An element has a pair of positive and negative electrodes, each comprising a collector made of a metallic foil having a carbon-containing electrode layer formed thereon, the electrodes rolled up with a separator interposed therebetween to form a pair of electrode terminations at opposite sides of the element. A dimension of one of the electrode terminations is set shorter than that of the other electrode termination. This structure achieves an increase in capacitance and decrease in resistance since it can increase an effective area of electrode surfaces under a restricted condition of keeping the same height of the element as it is placed inside a casing of given dimensions.