Flexible Multi-Cell Ultracapacitor Design for Volumetric Efficiency

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Solution Overview

Problem

Conventional ultracapacitors are often bulky and have low capacitance and high equivalent series resistance, making them inefficient for various applications, and existing flexible ultracapacitors struggle with volumetric efficiency and electrical performance.

Innovation Solution

The development of an ultracapacitor design featuring two electrochemical cells connected in parallel, with carbonaceous material-coated current collectors and a nonaqueous electrolyte, housed in a thin, flexible package, which reduces bulk and enhances capacitance and low ESR values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional rigid metal containers are used for ultracapacitors, then structural strength is improved, but device volume and bulk increase

Engineering Contradiction:

Improvestructural strengthVSAvoiddevice volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent replaces rigid metal containers with flexible packaging materials including laminated films, foils, and thin-walled structures. These flexible packages maintain structural integrity while significantly reducing device volume and bulk, allowing the ultracapacitor to be more easily integrated into various applications with space constraints.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If flexible housing is used for ultracapacitors, then adaptability is improved, but volumetric efficiency and electrical performance deteriorate

Engineering Contradiction:

ImproveadaptabilityVSAvoidvolumetric efficiency

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent employs composite packaging structures combining multiple materials layers (e.g., laminated films with polymer, metal, and barrier layers) that provide both flexibility for adaptability and dense construction for improved volumetric efficiency. This composite approach maintains electrical performance while enabling flexible form factors.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements a nested electrode configuration where multiple electrode layers are stacked and rolled or folded within the flexible package, maximizing the use of available volume. This nesting approach increases capacitance density and volumetric efficiency while maintaining the flexible form factor.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If conventional ultracapacitor designs are used, then manufacturing simplicity is maintained, but capacitance density and electrical performance improve

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcapacitance density

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent divides the ultracapacitor into multiple electrochemical cells connected in parallel, each cell containing electrodes with carbonaceous material coatings. This segmentation allows for optimized electrode construction in each cell while maintaining overall manufacturing simplicity through modular assembly, resulting in higher total capacitance density.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent modifies key parameters including using nonaqueous electrolytes, implementing carbonaceous material coatings on current collectors, and optimizing electrode porosity and surface area. These parameter changes significantly improve capacitance density and electrical performance while remaining compatible with existing manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

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 ultracapacitor achieves high volumetric efficiency with capacitance values of 6 Farads per cubic centimeter or more and low ESR values, maintaining performance even at high temperatures and under extreme conditions.

Implementation Method 1

The ultracapacitor also contains a nonaqueous electrolyte that is in ionic contact with the first electrode, second electrode, and third electrodes

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 2

a first electrode that contains a current collector having opposing sides coated with a carbonaceous material

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS10446328B2Multi-cell ultracapacitor

Publication Date: 2019.10.15 KYOCERA AVX COMPONENTS CORP

AI summary

An ultracapacitor that comprises a first and second electrochemical cell that are connected in parallel is provided. The cells are define by a first electrode that contains a current collector having opposing sides coated with a carbonaceous material, a second electrode that contains a current collector having opposing sides coated with a carbonaceous material, and a separator positioned between the first electrode and the second electrode. The second cell is by the second electrode, a third electrode that contains a current collector having opposing sides coated with a carbonaceous material, and a separator positioned between the second electrode and the third electrode. The ultracapacitor also contains a nonaqueous electrolyte that is in ionic contact with the electrodes and contains a nonaqueous solvent and an ionic liquid. A package encloses the first cell, the second cell, and the nonaqueous electrolyte.