Embossed Electrode Layer for High Volume Capacitance
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Solution Overview
Problem
Existing electrochemical capacitors face challenges in achieving high volume capacitance due to insufficient compression of polarizable electrode layers using smooth rollers, which limits their capacity to at least 17 F/cm3.
Innovation Solution
A manufacturing method and apparatus that involves forming a polarizable electrode layer on a current collector, subjecting its surface to embossment using a roller with a rugged pattern, and then flattening the embossed surface to enhance compression and prevent grain loss, ensuring a high volume capacitance of at least 17 F/cm3.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If roll press with smooth roller is used to compress polarizable electrode layer, then compression is applied, but volume capacitance is insufficient (cannot achieve at least 17 F/cm3)
Solution Approach 1:
The invention applies a rugged pattern (curved/irregular surface) to the roller instead of a smooth surface. This rugged pattern creates embossment effects that significantly enhance compression of the polarizable electrode layer, enabling volume capacitance of at least 17 F/cm3 while maintaining ease of manufacture through a modified roller design
2Manufacturing precision
If embossment work is applied to compress polarizable electrode layer, then volume capacitance increases, but porous grains may fall off and reliability decreases
Solution Approach 1:
The invention applies embossment work followed by flattening work. The embossment provides sufficient compression for high volume capacitance, while the subsequent flattening process secures the porous grains by reducing the embossment depth, thus maintaining reliability while achieving the required capacitance performance
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 method effectively compresses the polarizable electrode layer, achieving a high volume capacitance while maintaining reliability by preventing porous grain loss and reducing damage to the current collector.
Implementation Method 1
the polarizable electrode layer needs to be compressed by roll press or the like after the formation thereof by the coating
Implementation Method 2
subjecting a front surface of the polarizable electrode layer formed on the current collector, to an embossment work
Implementation Method 3
flattening the front surface of the polarizable electrode layer as has undergone the embossment work
Data Source
AI summary
A manufacturing method for an electrode for an electrochemical capacitor according to the present invention comprises a first process (steps S1-S3) for forming a polarizable electrode layer on a current collector, a second process (step S4) for subjecting the front surface of the polarizable electrode layer formed on the current collector, to an embossment work, and a third process (step S5) for flattening the front surface of the polarizable electrode layer as has undergone the embossment work. In this manner, in the invention, the front surface of the polarizable electrode layer undergoes the embossment work, so that the polarizable electrode layer is effectively compressed, and it is consequently permitted to achieve a high volume capacitance of at least 17 F/cm3. Moreover, after the embossment work, the resulting embossment is flattened, so that porous grains contained in the polarizable electrode layer are prevented from falling off, and it is permitted to ensure a high reliability.