Flexible Printed Circuit Supercapacitor with Barrier Layer
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Solution Overview
Problem
Current supercapacitors are bulky, suffer from electrolyte swelling, and have a wrong form factor for integration into portable electronic devices, making them impractical for use in miniaturized electronic devices due to size and performance requirements.
Innovation Solution
A flexible printed circuit (FPC) structure is used to integrate an electrical storage cell, with first and second circuit boards bonded together under curing, employing a barrier layer to inhibit electrolyte interaction with bonding layers, forming a chamber with electrolyte, and using high surface area materials for capacitive elements to enhance energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional capacitors or electrolytic capacitors are used, then the device structure is simple, but they cannot deliver sufficient current bursts for optimal flash and speaker performance
Solution Approach 1:
The capacitor is segmented into multiple thin layers stacked together, with each layer containing electrodes and electrolyte. This segmentation allows the capacitor to achieve high current delivery capability while maintaining a compact form factor suitable for portable devices.
Solution Approach 2:
The invention uses composite materials including conductive polymers for electrodes, gel electrolytes, and flexible substrates. These composite materials enable the capacitor to deliver high current bursts while being flexible and miniaturized for integration into portable electronic devices.
2Power
If supercapacitors are used to increase current delivery, then power performance improves, but they become bulky and suffer from electrolyte swelling
Solution Approach 1:
The capacitor transitions from a planar structure to a three-dimensional stacked configuration with multiple layers. This dimensional change allows high capacitance and current delivery in a compact volume by utilizing vertical stacking rather than lateral expansion.
Solution Approach 2:
The invention uses flexible substrates and thin film electrodes to create a miniaturized capacitor structure. The flexible nature allows the capacitor to be integrated into portable devices without rigid housing, reducing overall device volume while maintaining high power output.
3Power
If supercapacitors are integrated into portable devices, then power performance improves, but they have wrong form factor and require complex processing steps
Solution Approach 1:
The capacitor structure is merged with the flexible printed circuit board, combining power storage and signal routing functions into a single integrated component. This eliminates separate mounting steps and reduces manufacturing complexity while maintaining high power capability.
Solution Approach 2:
The flexible circuit board serves multiple functions: it provides structural support, electrical connectivity, and capacitor housing. This multi-functionality reduces the number of separate components and assembly steps required, simplifying integration into portable devices.
4Use of energy by moving object
If electrolyte is used in the capacitor, then energy storage capacity increases, but electrolyte swelling occurs during curing
Solution Approach 1:
A barrier layer is introduced as an intermediary between the electrolyte and the bonding adhesive. This barrier layer prevents direct contact between the electrolyte and adhesive, eliminating swelling issues while allowing the capacitor to maintain high energy storage capacity through proper electrolyte containment.
Solution Approach 2:
The invention uses a thin barrier layer that is consumed or degraded during the bonding process to protect the electrolyte. This disposable barrier layer prevents electrolyte contamination of the adhesive, ensuring long-term stability without requiring complex protective structures.
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 approach allows for the creation of compact, efficient supercapacitors that can deliver high current bursts, extending battery life and improving device performance while maintaining a flexible form factor suitable for portable electronics.
Implementation Method 1
the one or more first layers are configured to inhibit interaction of the electrolyte with the one or more second layers during curing
Implementation Method 2
the bonding defining a chamber therebetween with the electrodes therein and facing one another, the chamber comprising the electrolyte
Data Source
AI summary
An apparatus comprising:first and second circuit boards with respective electrodes thereon, the first and second circuit boards in a bonded configuration;one or more first layers positioned to be proximal to the one or more of the electrodes;electrolyte proximal to the respective electrodes;one or more second layers configured to provide for the bonded configuration in which the first and second circuit boards are bonded together, under curing, such that the respective one or more first layers are positioned between the one or more second layers and the electrodes, the bonding defining a chamber therebetween with the electrodes therein and facing one another, the chamber comprising the electrolyte; andwherein the one or more first layers are configured to inhibit interaction of the electrolyte with the one or more second layers during curing.