Microwave Plasma CVD Graphene Electrode for Supercapacitor Energy Density
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Solution Overview
Problem
Existing electrostatic double-layer capacitors and hybrid supercapacitors face limitations due to low energy density and high energy storage costs, which restrict their application scope.
Innovation Solution
A manufacturing method for an energy storage element electrode involves forming multi-layer graphene walls using microwave plasma chemical vapor deposition and subsequent electrochemical activation treatment to intercalate ions between graphene walls, thereby enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple processes are performed to improve the physical and chemical properties of graphene to increase energy density, then the energy density of the energy storage element is improved, but the process complexity and manufacturing costs increase significantly
Solution Approach 1:
The invention changes the key parameter of gas flow rate ratio (carrier gas to carbon precursor gas) to control the formation of multi-layer graphene walls with specific interlayer spacing. By adjusting this single parameter within the range of 1:10 to 10:1, the process achieves improved energy density without requiring multiple complex treatment steps, thus resolving the contradiction between energy density improvement and process complexity
Solution Approach 2:
The invention utilizes the inherent porous structure of multi-layer graphene walls with controlled interlayer spacing (0.34 nm to 0.52 nm) to accommodate electrolyte ions. This porous structure is formed directly during the CVD process by controlling the carbon precursor gas flow, eliminating the need for subsequent complex pore-forming treatments while achieving high energy density
2Quantity of substance
If multiple processes are performed to improve the physical and chemical properties of graphene to increase energy density, then the energy density of the energy storage element is improved, but the manufacturing time and costs increase
Solution Approach 1:
The invention performs the interlayer spacing adjustment action during the initial graphene growth phase by controlling the gas flow rate ratio in the CVD process. This preliminary action eliminates the need for subsequent separate treatment steps, significantly reducing the total manufacturing time while achieving the desired energy density improvement
Solution Approach 2:
By changing the gas flow rate ratio parameter during a single CVD process run, the invention achieves both graphene formation and interlayer spacing optimization in one step, reducing the number of process steps and overall manufacturing time while improving energy density
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 increases the surface area and wettability of the electrode, leading to improved energy density of the energy storage element while reducing process complexity and costs.
Implementation Method 1
Multi-layer graphene walls are formed on the substrate through microwave plasma chemical vapor deposition
Implementation Method 2
Multi-layer graphene walls are formed on the substrate through microwave plasma chemical vapor deposition
Implementation Method 3
The substrate containing the multi-layer graphene walls is immersed in an electrolyte solution to perform electrochemical activation treatment, so that ions in the electrolyte solution are intercalated between adjacent graphene walls
Data Source
AI summary
A manufacturing method of an electrode of an energy storage element includes: providing a substrate into microwave plasma equipment; introducing a carrier gas and a carbon precursor gas into the microwave plasma equipment; forming multi-layer graphene walls on the substrate through microwave plasma chemical vapor deposition; and immersing the substrate containing the multi-layer graphene walls in an electrolyte solution to perform electrochemical activation treatment, so that ions in the electrolyte solution are intercalated between adjacent graphene walls. A volume ratio of the carrier gas to the carbon precursor gas is 1:10 to 10:1. An electrode of an energy storage element is also provided.