Carbon Nanotube Electrode Mechanical Integration via Etched Foil

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Solution Overview

Problem

Existing electrical double layer capacitors with carbon nanotube electrodes face challenges in achieving excellent capacitance characteristics due to the use of resin binders, which require complex and time-consuming attachment processes.

Innovation Solution

The integration of paper molded carbon nanotubes with a substrate using bumps and indentations on the surface of an etched foil or porous metal body, eliminating the need for resin or conductive auxiliary materials, thereby reducing electrical resistance and enhancing capacitance characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If resin binders are used to attach carbon nanotubes to the electrode substrate, then the structural integrity of the electrode is improved, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the resin binder component from the electrode structure, replacing it with a direct mechanical attachment method using bumps and indentations. This removes the harmful effect of complex manufacturing processes while maintaining structural integrity through purely physical means.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention introduces bumps and indentations as an intermediary mechanical feature that mediates the attachment between carbon nanotubes and the electrode substrate. This intermediary structure enables strong bonding without requiring resin binders, thus simplifying the manufacturing process while maintaining structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If resin binders are used to attach carbon nanotubes to the electrode substrate, then the structural integrity of the electrode is improved, but the production time increases

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the chemical bonding mechanism (resin adhesion) with a mechanical interlocking system (bumps and indentations). This substitution eliminates time-consuming chemical processes while maintaining strong structural integrity, thereby improving production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If resin binders and conductive auxiliary materials are used, then the electrode structure is stabilized, but the electrical resistance increases

Engineering Contradiction:

Improveelectrode structure stabilityVSAvoidelectrical resistance

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The invention extracts and eliminates resin binders and conductive auxiliary materials from the electrode structure. By removing these insulating or semi-insulating materials, the invention reduces electrical resistance while maintaining structural stability through direct mechanical attachment of carbon nanotubes to the substrate.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention creates a composite structure where carbon nanotubes are directly attached to the electrode substrate through bumps and indentations, forming a conductive network without insulating resin binders. This composite architecture maintains structural stability while ensuring low electrical resistance through direct conductive pathways.

Inventive Principle:

Principle #40Composite materials

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 method allows for the production of electrical double layer capacitor electrodes with improved capacitance and reduced electrical resistance, achieving higher energy and power densities while simplifying the manufacturing process.

Implementation Method 1

integrated with a substrate constituting a collector, by means of bumps and indentations on the surface of the substrate

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS8824120B2Electrode for electric double layer capacitor and method for producing the same

Publication Date: 2014.09.02 NIPPON CHEMI CON CORP

AI summary

An electrical double-layer capacitor electrode with excellent capacitance characteristics is obtained together with a manufacturing method therefor. Paper-molded sheet of carbon nanotubes is integrated with etched foil constituting a collector, by means of bumps and indentations formed on the surface of etched foil to prepare an electrical double-layer capacitor electrode. Alternatively, carbon nanotubes grown around core catalyst particles on substrate are integrated with etched foil by means of bumps and indentations formed on the surface of etched foil to prepare an electrical double-layer capacitor electrode. To manufacture these electrodes, this carbon nanotube sheet or substrate with carbon nanotubes grown thereon is laid over bumps and indentations on the surface of etched foil, and the sheet or substrate and the foil are pressed under 0.01 to 100 t/cm2 of pressure to integrate the carbon nanotubes with the etched foil.