Capacitor Electrode Conductive Layer Flake Graphite Density
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Solution Overview
Problem
Conventional electric double layer capacitors face challenges in maintaining long-term charge and discharge characteristics due to interfacial resistance and electrolyte permeation, leading to substrate corrosion and performance deterioration over repeated charging and discharging cycles.
Innovation Solution
A capacitor electrode configuration featuring a conductive layer with densely packed flake graphite, a substrate with improved adhesion properties, and a specific binder composition to prevent electrolyte penetration and enhance adhesion strength, ensuring the conductive layer's integrity and preventing substrate corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive layer is formed between the current collector and polarizable electrode layer to reduce interfacial resistance, then electrical conductivity is improved, but the conductive layer may allow electrolyte permeation causing substrate corrosion
Solution Approach 1:
The conductive layer is formed as a composite material comprising carbon black particles and binder, creating a dense structure that simultaneously provides electrical conductivity and prevents electrolyte permeation. The composite structure combines the conductive properties of carbon black with the protective function of the binder matrix.
Solution Approach 2:
The density of the conductive layer is controlled to be greater than 1.1 g/cm³ by optimizing the particle size distribution and packing density of carbon black. This parameter change ensures the conductive layer is dense enough to prevent electrolyte penetration while maintaining electrical conductivity.
2Object-affected harmful factors
If the conductive layer density is increased to prevent electrolyte permeation, then substrate corrosion is prevented, but manufacturing complexity increases
Solution Approach 1:
The density of the conductive layer is optimized to be greater than 1.1 g/cm³ through controlled particle packing. This parameter optimization achieves effective electrolyte barrier function without requiring overly complex multi-layer structures or additional protective components.
Solution Approach 2:
The conductive layer serves as an intermediary between the current collector and polarizable electrode layer, performing multiple functions simultaneously: providing electrical conductivity, preventing electrolyte permeation, and maintaining structural integrity. This single intermediary layer avoids the need for multiple separate protective layers.
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
The proposed configuration effectively reduces interfacial resistance, maintains charge and discharge characteristics over time, and extends the life of the capacitor by preventing electrolyte contact with the substrate, thereby enhancing the capacitor's reliability and longevity.
Implementation Method 1
The electrode layer is allowed to adsorb and desorb ions on a surface thereof
Implementation Method 2
an electrolyte solution is prevented from permeating through the conductive layer
Data Source
AI summary
A capacitor electrode includes a substrate having electrical conductivity, a conductive layer formed on a surface of the substrate, and an electrode layer formed on the conductive layer. The electrode layer is allowed to adsorb and desorb ions on a surface thereof. The conductive layer contains flake graphite. A density of the conductive layer is greater than 1.1 g/cm3. An average particle size D50 of the flake graphite, which is measured by using a dynamic light scattering method, is less than or equal to 10 μm.