Fine-Array Porous Electrode Material for Supercapacitors
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Solution Overview
Problem
Conventional electrical energy storage devices, such as supercapacitors and batteries, face limitations in energy capacity and efficiency due to non-uniform electrode materials leading to resistance heating and uneven electrolyte distribution, which restricts stable charge storage and high power output.
Innovation Solution
The development of a fine-array porous electrode material with a high surface-area-to-volume ratio, uniform pore size, and metal or metal oxide composition, which enhances mechanical strength, electrolyte diffusion, and reduces resistance, allowing for increased energy storage capacity and improved charge/discharge rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional porous carbon electrode materials with large particle sizes (0.5 μm-100 μm) and high porosity (90-95%) are used, then the relative surface area is increased, but the pore size variation (25 nm-1000 nm) causes non-uniform electrolyte distribution and local resistance heating
Solution Approach 1:
The patent applies porous materials with controlled pore structures, specifically using porous metals (aluminum, nickel, titanium) and metal oxides with pore sizes uniformly distributed between 0.1-10 μm. This controlled porosity enables both high surface area and uniform electrolyte distribution, resolving the contradiction between increasing surface area and maintaining distribution uniformity.
Solution Approach 2:
The patent changes the pore size parameter from the conventional 25 nm-1000 nm range to a more controlled 0.1-10 μm range with coefficient of variation less than 20%. This parameter optimization ensures uniform electrolyte diffusion while maintaining high surface area, thereby improving reliability and reducing local resistance heating.
2Area of stationary object
If porous materials with high porosity (90-95%) are used to increase surface area, then energy storage capacity is enhanced, but mechanical strength is reduced
Solution Approach 1:
The patent employs composite material structures combining porous metals with metal oxides (such as aluminum with aluminum oxide, nickel with nickel oxide, or titanium with titanium oxide). These composites provide both the high surface area needed for energy storage and the mechanical strength required for structural integrity, resolving the contradiction between surface area and strength.
Solution Approach 2:
The patent applies different materials to different regions of the electrode structure - porous metal providing mechanical framework and conductivity, while metal oxide coatings provide additional surface area and electrochemical activity. This local differentiation allows simultaneous optimization of strength and surface area.
3Ease of manufacture
If non-uniform porous materials are used, then manufacturing is simplified, but resistance heating increases due to uneven resistance distribution
Solution Approach 1:
The patent optimizes the pore size parameter to be uniformly distributed between 0.1-10 μm with coefficient of variation less than 20%, which can be achieved through controlled fabrication processes. This uniformity ensures even current distribution and reduces local resistance heating while maintaining ease of manufacture through scalable production methods.
4Quantity of substance
If conventional carbon electrode materials are used, then energy storage capacity is increased through high porosity, but charge storage stability is reduced due to non-uniform electrolyte diffusion
Solution Approach 1:
The patent uses porous metals and metal oxides with controlled pore sizes (0.1-10 μm) that facilitate uniform electrolyte diffusion throughout the electrode structure. This uniform diffusion ensures stable charge storage while maintaining high energy storage capacity through the high surface area provided by the porous structure.
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 fine-array porous electrode material significantly increases energy storage capacity, reduces electrical resistance, and extends cycle life by enabling stable electrolyte distribution and efficient electron transfer, resulting in higher power output and reduced energy waste.
Implementation Method 1
the significantly-larger void space of the fine-array porous electrode material makes it possible to have an even diffusion of electrolytes within the electrode materials
Implementation Method 2
allowing the electrical charges to be stably stored on the surface of the electrodes
Data Source
AI summary
An electrode material includes a fine-array porous material. The fine-array porous material includes a plurality of pores having a substantially uniform size of <1000 μm, with a variation of <20%, and comprises a metal such as Ni, Al, Ti, Sn and Mn. The metal fine-array porous electrode material can be surface-treated to form a metal oxide on the surface of the porous electrode material, or be coated with a metal oxide including RuO2, TaO. An electrical energy storage apparatus, such as a supercapacitor or a lithium battery, containing the fine-array porous electrode material can have significantly improved performances as compared with conventional materials.