Comb-Shaped Battery Electrodes for High Capacitance Density
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Solution Overview
Problem
Current ultra-capacitor batteries face limitations in capacitance density and performance due to the lack of efficient energy storage and charging times, particularly in heavy-duty energy consumption applications.
Innovation Solution
The development of an ultra-capacitor battery with a novel structure featuring intersecting comb-like cathodes and anodes, where a graphene layer is deposited on the comb-shaped substrates, reducing the distance between the anode and cathode and enhancing capacitance density, combined with a hermetically sealed container filled with an electrolyte solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional battery structures are used, then manufacturing simplicity is maintained, but capacitance density and energy storage capability are limited
Solution Approach 1:
The patent divides the battery electrodes into multiple comb-like segments with alternating fingers. This segmentation increases the effective surface area and capacitance density while maintaining a manageable structural complexity through modular assembly of the comb fingers and substrates.
Solution Approach 2:
The patent transitions from traditional planar electrode structures to three-dimensional comb-like structures extending in the vertical dimension. This dimensional change dramatically increases the electrode surface area and capacitance density without proportionally increasing the footprint area of the battery.
2Quantity of substance
If electrode distance is reduced to increase capacitance density, then energy storage capability improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent combines multiple electrode functions into integrated comb-like structures where the insulating substrates and conductive fingers are formed as unified components. This merging reduces the number of separate parts requiring alignment and simplifies manufacturing while maintaining precise electrode spacing.
Solution Approach 2:
The patent optimizes the geometric parameters of the comb structures, including finger width, spacing, and length, to achieve the desired capacitance density. By carefully controlling these parameters during manufacturing, the design achieves high energy storage capability while maintaining feasible manufacturing precision requirements.
3Quantity of substance
If graphene layer is deposited on comb-shaped substrates, then energy storage capability increases, but manufacturing process complexity increases
Solution Approach 1:
The patent forms the comb-like electrode structures with insulating substrates and conductive fingers before depositing the graphene layer. This preliminary structuring allows the graphene to be deposited as a thin conformal coating on pre-formed surfaces, simplifying the overall manufacturing process compared to attempting to form complex 3D structures after graphene deposition.
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 ultra-capacitor battery achieves fast charge-discharge times, high energy storage capability, and long cycle life, delivering improved performance and efficiency in energy storage and delivery.
Implementation Method 1
a graphene layer is deposited on the comb-shaped substrates
Implementation Method 2
an electrolyte solution filling the air gap and the container
Data Source
AI summary
A method for manufacturing an ultra-capacity battery includes providing cathodes and anodes. Providing the cathodes includes providing a first substrate having a first surface and a second surface opposite the first surface, forming a plurality of first combs perpendicular to the first surface of the first substrate and arranged at a first interval along a first direction, forming a graphene layer on the first combs and on the first surface of the first substrate. Providing the anodes includes providing a second substrate having a first surface and a second surface, forming a patterned insulating film on the first surface of the second substrate exposing a portion of the first surface of the second substrate, etching the exposed portion of the first surface of the second substrate to form a body portion and a plurality of second combs perpendicular to the body portion.