Thin Electrochemical Device Active Layer Thickness Optimization
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Solution Overview
Problem
Electrochemical devices, such as capacitors and batteries, face challenges in miniaturization due to the risk of chips or cracks in the active substance layer, leading to short-circuiting and reduced electrical properties when made thinner.
Innovation Solution
The electrochemical device is designed with an element thickness of 600 μm or less and an active substance layer thickness of 80% or less of the element, ensuring flexibility while preventing chips and cracks, and maintaining electrical properties by setting the active substance layer thickness to 10% or more of the element thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the element thickness is reduced to make the electrochemical device thinner, then the device becomes more flexible and easier to miniaturize, but the active substance layer becomes more prone to chips and cracks, leading to short-circuiting and reduced electrical properties
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness ratio between the active substance layer and the element. Specifically, it sets the active substance layer thickness to 80% or less of the element thickness, which prevents chips and cracks while maintaining electrical properties. This quantitative parameter optimization resolves the contradiction between thinness and reliability.
2Reliability
If the active substance layer thickness is increased to improve electrical properties, then the electrical characteristics are enhanced, but the active substance layer becomes more prone to chips and cracks, especially in thin devices
Solution Approach 1:
The patent resolves this contradiction by establishing an optimal parameter range: the active substance layer thickness is set to 80% or less of the element thickness. This parameter optimization ensures that the active substance layer is thick enough to maintain good electrical characteristics while thin enough to resist chips and cracks during bending.
3Length of moving object
If the active substance layer is made too thin to achieve a thinner device, then the device becomes more flexible and thinner, but manufacturing uniformity becomes difficult and electrical properties may decline
Solution Approach 1:
The patent addresses this contradiction by setting the active substance layer thickness to a specific proportion (80% or less of the element thickness) rather than an absolute thin value. This proportional parameter setting ensures that the active substance layer remains thick enough for uniform manufacturing while still achieving the overall thinness goal for the device.
Data Source
AI summary
An electrical double layer capacitor comprises an element and a case which houses the element. The element has an anode charge collector, anode, separator, cathode and cathode charge collector. The anode and cathode consist of a porous layer containing electrically conducting porous particles as a constituent material. The anode charge collector is disposed in electrical contact with the anode. The cathode charge collector is disposed in electrical contact with the cathode. The thickness of the element is 600 μm or less. The sum of the anode thickness and cathode thickness is set to 80% or less of the thickness of the element.