High Density Electrode Protrusion Design for EDLC Energy Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric double layer capacitor electrodes face a challenge in maintaining surface area when forming through holes, leading to reduced contact area with active materials, which limits energy density.
Innovation Solution
A high density electrode design featuring a through-type aluminum sheet with spaced through holes and protrusion members that extend to both sides, allowing for increased contact area with active material sheets through bonded protrusion members, preventing surface area loss and enhancing electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If through holes are formed in the aluminum current collector to increase contact area with active materials, then the energy density is improved, but the surface area of the aluminum current collector is lost
Solution Approach 1:
The invention transitions from a two-dimensional flat contact surface to a three-dimensional structure by forming protrusion members that extend from the aluminum current collector. These protrusions create additional contact surfaces in the vertical dimension, allowing increased contact area with active materials without sacrificing the horizontal surface area of the aluminum collector.
Solution Approach 2:
The aluminum current collector is segmented into multiple protrusion members that are spaced apart from each other. This segmentation allows the active material to contact multiple discrete protrusion surfaces, effectively increasing the total contact area while maintaining the overall surface integrity of the aluminum collector.
2Area of stationary object
If photolithography process is used to form patterns with through holes in aluminum current collector, then contact area with active materials is increased, but the manufacturing complexity and process steps are increased
Solution Approach 1:
The invention extracts and eliminates the photolithography process from the manufacturing sequence. Instead of using complex photoresist coating, exposure, and development steps, the protrusion patterns are formed directly through etching or forming processes, significantly simplifying the manufacturing process while achieving the same contact area enhancement.
Solution Approach 2:
The complex chemical and optical processes of photolithography are replaced with simpler mechanical or direct etching processes. The protrusion members are formed through controlled material removal or deposition, substituting the multi-step photolithographic system with a more straightforward manufacturing approach.
Data Source
AI summary
A high density electrode includes a through type aluminum sheet, a plurality of first hollow protrusion members protruded to one side of the through type aluminum sheet, a plurality of second hollow protrusion members protruded to the other side of the through type aluminum sheet, a first active material sheet bonded to the first surface of the through type aluminum sheet, and a second active material sheet bonded to the second surface of the second surface of the through type aluminum sheet.