Electric Double Layer Capacitor with Insulating Protrusions
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Solution Overview
Problem
Conventional electric double layer capacitors face limitations in energy storage efficiency and output characteristics due to the use of porous separators, which increase ion transport distances and reduce conductivity, and require additional balancing circuits for series connections, leading to charging deviations and potential dielectric breakdown.
Innovation Solution
The electric double layer capacitor design eliminates the separator by using insulating material protrusions on the current collector plates to physically separate the electrodes, reducing ion transport distances and improving conductivity, while allowing ion transport through the electrolyte, and connects cells in series without external circuit boards to minimize connection resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous separator is disposed between the positive electrode layer and the negative electrode layer to prevent electrical contact, then the electrodes are physically separated and insulated, but the ion transport distance increases and conductivity degrades
Solution Approach 1:
The patent extracts and removes the porous separator from the capacitor structure, replacing it with a different insulation mechanism. The separator is completely taken out of the system and its insulation function is achieved through alternative means (electrode structure design and insulating coating), thereby eliminating the negative impact on ion transport while maintaining electrical insulation.
Solution Approach 2:
The patent introduces an insulating coating layer as an intermediary substance applied directly on the electrode surfaces. This coating layer serves as the mediator that provides electrical insulation between the positive and negative electrodes without requiring a separate porous separator, thus maintaining insulation while allowing direct ion transport through the electrolyte.
2Reliability
If the separator thickness is increased to improve porosity and insulation characteristics, then the insulation performance improves, but the ion transport distance increases and energy storage efficiency degrades
Solution Approach 1:
The patent extracts the separator from the system entirely, eliminating the trade-off between separator thickness and ion transport distance. The insulation function is achieved through a different mechanism (insulating coating on electrodes) that does not require thick porous structures, thereby maintaining insulation performance while minimizing ion transport distance and maximizing energy storage efficiency.
Solution Approach 2:
The patent changes the fundamental parameter of insulation implementation from thick porous separator to thin insulating coating. This parameter change transforms the insulation mechanism from relying on physical thickness to relying on material properties of the coating layer, thereby achieving effective insulation with minimal impact on ion transport and energy storage efficiency.
3Temperature
If multiple capacitor cells are connected in series using external circuit boards to achieve high voltage, then the voltage increases, but the connection resistance increases and charging deviations occur
Solution Approach 1:
The patent merges multiple capacitor cells into a single integrated structure where the cells are directly connected without external circuit boards. The electrodes of adjacent cells are positioned to face each other with direct electrical connection, combining multiple cells into one unified capacitor unit. This merging eliminates connection resistance and charging deviations while achieving high voltage through the series connection of multiple cell structures.
Solution Approach 2:
The patent makes the capacitor structure multi-functional by integrating both the capacitor cell structure and the connection function into a single design. The electrode structure serves dual purposes: as the active capacitor element and as the connection medium between cells, eliminating the need for separate connection components and reducing overall system complexity.
4Reliability
If a porous separator is used to separate the electrodes, then electrical insulation is achieved, but the manufacturing process becomes more complex and costs increase
Solution Approach 1:
The patent extracts and removes the porous separator from the manufacturing process, significantly simplifying the fabrication steps. Instead of requiring separate separator materials and assembly steps, the insulation function is integrated directly into the electrode structure through coating application, which is a more straightforward and cost-effective manufacturing process.
Solution Approach 2:
The patent merges the insulation function with the electrode structure itself by applying insulating coatings directly on the electrode surfaces. This combination eliminates the need for separate separator components and their associated manufacturing steps, thereby simplifying the overall manufacturing process while maintaining effective electrical insulation.
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 design enhances energy storage and output performance, reduces manufacturing costs, and eliminates the need for balancing circuits, improving durability and efficiency by minimizing contact resistance and avoiding dielectric breakdown.
Implementation Method 1
a positive electrode layer with a separator, wherein the separator is made of an insulating material, protrudes convexly from one surface of the positive current collector plate in a continuous pattern of a predetermined design, and has a convex shape in which a repeated pattern is formed in length and width directions of the positive current collector plate
Implementation Method 2
the capacitor container is filled with an electrolyte so that the positive electrode layer and the negative electrode layer are connected in terms of transport of positive ions and negative ions of the electrolyte
Implementation Method 3
a Helmholtz layer having a solvent molecule thickness of the electrolyte 160 (several angstroms from 0.3 nm to 0.8 nm), in which positive charges of the positive electrode layer 122 and negative ions of the electrolyte 160 are disposed and accumulated to face each other on the positive electrode layer 122
Data Source
AI summary
An electric double layer capacitor includes a plurality of current collector plates, an electrode layer formed on one surface of each of the current collector plates, and a plurality of separators which extend through the electrode layer from one surface of each of the current collector plates in a continuous pattern of a predetermined design and in which a repeated pattern is formed in the length and width directions of the current collector plates.