Bendable Supercapacitor Electrode with Staple Fasteners
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Solution Overview
Problem
Conventional supercapacitors are rigid and inflexible due to manufacturing methods that limit electrode materials and packaging, preventing them from being bendable or adaptable for use in portable applications.
Innovation Solution
A supercapacitor structure featuring bendable electrodes made of carbon fabric and electrically conductive current collectors secured with staple-shaped fasteners or metallic wires, allowing for flexible and low electrical resistance, packaged in a flexible bag with a separator and electrolyte solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is applied to press the laminate electrode as thin as possible, then internal electrical resistance is reduced, but the capacitor becomes rigid and inflexible
Solution Approach 1:
The patent uses a flexible laminate electrode structure composed of multiple thin layers (carbon fabric, current collector, separator) that can be bent and deformed. The flexible bag packaging and flexible printed circuit boards further contribute to the overall flexibility, allowing the capacitor to adapt to various shapes while maintaining low electrical resistance through the thin-layer design.
Solution Approach 2:
The laminate electrode employs composite materials including carbon fabric, electrically conductive current collector, and separator member, creating a multi-material structure that combines electrical conductivity with mechanical flexibility. This composite approach allows the electrode to maintain low resistance while being bendable and adaptable.
2Ease of manufacture
If conventional manufacturing methods are used with limited electrode materials and package methods, then manufacturing is simpler, but the capacitor cannot be flexible or bendable
Solution Approach 1:
The electrode is segmented into multiple discrete layers (carbon fabric element, current collector element, separator member) that are stacked and bonded together. This segmentation allows each layer to contribute specific properties while the overall structure remains flexible and manufacturable using standard lamination processes.
Solution Approach 2:
The patent employs flexible packaging materials and thin-film construction throughout the capacitor structure, including the flexible bag and flexible printed circuit boards, enabling the entire device to be bent and shaped without compromising functionality or manufacturing feasibility.
3Reliability
If the electrode is made thin to reduce resistance, then electrical performance improves, but the structure becomes more fragile and difficult to manufacture
Solution Approach 1:
Multiple thin layers are merged into a single laminate structure through bonding processes, combining the carbon fabric, current collector, and separator into one integrated electrode assembly. This merging maintains the low resistance benefits of thin layers while creating a unified structure that is easier to handle and manufacture.
Solution Approach 2:
The laminate electrode uses composite material construction where multiple materials are bonded together in thin layers, achieving low electrical resistance while the composite structure provides mechanical strength and ease of manufacturing through standardized lamination techniques.
Data Source
AI summary
A laminate electrode of a bendable supercapacitor has a carbon fabric element and an electrically conductive current collector element secured by staple-shaped metallic fasteners or metallic wires so as to prevent two elements from being taken apart when the laminate electrode is bent.