Flexible Supercapacitor Electrode Surface Metalizing

Solution Overview

Problem

Traditional super capacitors face reduced flexibility and capacitance due to the use of binders between carbon powder and collector layers, leading to increased internal resistance.

Innovation Solution

A flexible super capacitor design featuring flexible electrodes with a carbon fiber layer and a directly formed collector layer through surface metalizing, eliminating the need for binders and enhancing carbon content and specific surface area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If binders are used to glue carbon powder on collector layer, then carbon powder can be fixed on collector layer, but flexibility is reduced and internal resistance is increased

Engineering Contradiction:

Improveadhesion strengthVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent removes the binder component from the electrode structure entirely. Instead of using binders to adhere carbon powder to the collector layer, the invention uses carbon fiber as the active material that is directly connected to the collector layer through surface metalizing, eliminating the binder and thus restoring flexibility while maintaining adhesion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical state and form of the carbon material from powdered carbon to carbon fiber. This parameter change allows the carbon to be directly metalized and connected to the collector layer without requiring binders, thereby improving flexibility and reducing internal resistance while maintaining strong adhesion.

Inventive Principle:

Principle #35Parameter changes

2Strength

If binders are used to glue carbon powder on collector layer, then carbon powder can be fixed on collector layer, but internal resistance is increased

Engineering Contradiction:

Improveadhesion strengthVSAvoidinternal resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent removes the binder component from the electrode structure entirely. Instead of using binders to adhere carbon powder to the collector layer, the invention uses carbon fiber as the active material that is directly connected to the collector layer through surface metalizing, eliminating the binder and thus restoring flexibility while maintaining adhesion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical state and form of the carbon material from powdered carbon to carbon fiber. This parameter change allows the carbon to be directly metalized and connected to the collector layer without requiring binders, thereby improving flexibility and reducing internal resistance while maintaining strong adhesion.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If carbon powder is used with binder, then electrode can be formed, but capacitance is reduced

Engineering Contradiction:

Improveelectrode formationVSAvoidcapacitance

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent changes the physical state and form of the carbon material from powdered carbon to carbon fiber. This parameter change allows the carbon to be directly metalized and connected to the collector layer without requiring binders, thereby improving flexibility and reducing internal resistance while maintaining strong adhesion.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure where carbon fiber is directly metalized with collector layer material. This composite approach eliminates the need for separate binder materials and creates a more efficient electrical connection, improving capacitance while maintaining ease of manufacture.

Inventive Principle:

Principle #40Composite materials

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 solution increases capacitance and maintains flexibility by directly forming a collector layer on the carbon fiber layer, resulting in higher capacitance and reduced internal resistance compared to traditional methods.

Implementation Method 1

surface metalizing the carbon fiber layer to form a collector layer on the surface of the carbon fiber layer

Methodology Applied

Scientific EffectSurface metalizing: Deposition (physical)

Data Source

PatentUS7936555B2Method for fabricating flexible super capacitor

Publication Date: 2011.05.03 TAIWAN TEXTILE RESEARCH INSTITUTE

AI summary

A flexible super capacitor including a pair of flexible electrodes and a separator film is disclosed. Each flexible electrode includes a carbon fiber layer and a collector formed on a surface of the carbon fiber layer. The pair of flexible electrodes has two outer surfaces, and the collector layers are formed on the outer surfaces of the pair of the flexible electrodes. The separator film is disposed between the flexible electrodes. The collector layer would be formed on the carbon fiber layer with surface metalizing the carbon fiber layer. A method for fabricating the flexible electrode of the flexible super capacitor is also disclosed.