Electric Double-Layer Capacitor Package with Resin Projections
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Solution Overview
Problem
Existing electrical storage device packages are inefficient in minimizing the use of expensive electrolytic solution, as the solution tends to spread and occupy unnecessary internal spaces.
Innovation Solution
The package design includes a body with a metallic and resin portion, featuring projections that narrow the closed space and reduce electrolytic solution usage, while also providing electrical insulation and improved moisture barrier properties using polymers like polyether ether ketone and polyphenylene sulfide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the package is designed with a simple tray-shaped body and lid structure, then the manufacturing is simple and cost-effective, but the electrolytic solution spreads and occupies unnecessary internal spaces increasing solution usage
Solution Approach 1:
The package body is divided into a metallic portion and a resin portion, with the resin portion containing projections that segment the internal space. This segmentation prevents electrolytic solution spreading while maintaining manufacturing efficiency through integrated molding of the resin portion.
Solution Approach 2:
The resin portion is strategically positioned at specific locations within the package body where electrolytic solution accumulation occurs. The local addition of resin material with projection structures provides space restriction exactly where needed, without complicating the overall package structure.
2Quantity of substance
If projections are added to the resin portion to reduce electrolytic solution space, then the solution usage is minimized, but the device complexity increases
Solution Approach 1:
The projections for space restriction and the electrical insulation functions are merged into a single resin portion structure. This integration achieves multiple objectives simultaneously without adding separate components, thereby minimizing device complexity while reducing electrolytic solution usage.
Solution Approach 2:
The resin portion serves multiple functions: it provides structural support, electrically insulates the lead-out terminals, and through its projections, restricts electrolytic solution space. This multi-functionality reduces the need for additional components and simplifies the overall device structure.
3Quantity of substance
If the resin portion is used to form projections for space restriction, then electrical insulation of lead-out terminals is achieved, but additional components are required increasing cost
Solution Approach 1:
The resin portion is molded as an integrated component that simultaneously provides electrical insulation for the lead-out terminals and forms projections to restrict electrolytic solution space. This merging eliminates the need for separate insulation components and projection structures, reducing manufacturing cost and complexity.
Data Source
AI summary
An electric double-layer capacitor having a capacitor element, a package defining a closed space accommodating the capacitor element, and electrolytic solution loaded in the closed space. The package includes a body and a lid, and the body has a metallic portion and a resin portion. The metallic portion includes two lead-out terminals electrically coupled to the capacitor element, and these two lead-out terminals are electrically isolated from each other by the resin portion. The resin portion includes two projections extending into the closed space, which make the closed space narrower and reduce the amount of loading of the electrolytic solution.