LDPE-Sulfur Composite Electrode for Processable Supercapacitors

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Solution Overview

Problem

Existing electrode materials for supercapacitors, such as polyaniline and polythiophene, are expensive and difficult to process, while sulfur, with its multiple oxidation states, has not been thoroughly investigated for its potential in hybrid composite materials for energy storage applications.

Innovation Solution

A hybrid composite material comprising branched polyethylene (LDPE) and elemental sulfur, where sulfur is substantially uniformly dispersed in the polymer matrix, enhancing thermo-mechanical properties and energy storage capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional polymers (polyaniline, polypyrrole, polythiophene) are used as electrode materials, then energy storage capability is achieved, but cost increases and processing difficulty increases

Engineering Contradiction:

Improveenergy storage capabilityVSAvoidprocessing difficulty

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameter from conventional conducting polymers to a hybrid composite of LDPE and sulfur. This parameter change maintains energy storage capability through sulfur's multiple oxidation states while dramatically improving ease of manufacture, as LDPE-sulfur composites can be processed using standard extrusion and molding techniques without specialized polymerization conditions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material system combining LDPE matrix with sulfur filler. This composite approach leverages the processability and mechanical properties of LDPE while incorporating the electrochemical energy storage functionality of sulfur, thereby achieving both energy storage capability and ease of manufacture through a synergistic material combination.

Inventive Principle:

Principle #40Composite materials

2Strength

If inorganic fillers (silica, ZnO, iron oxide, TiO2) are added to polymer matrix, then thermo-mechanical properties are improved, but cost increases

Engineering Contradiction:

Improvethermo-mechanical propertiesVSAvoidcost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces expensive inorganic fillers with sulfur, which is significantly cheaper and more abundant. Sulfur provides the necessary functional properties for energy storage at a fraction of the cost of traditional inorganic fillers like TiO2 or ZnO, making the composite material economically viable for large-scale production.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the filler material parameter from expensive inorganic oxides to elemental sulfur. This parameter substitution maintains or enhances thermo-mechanical properties while dramatically reducing material cost, as sulfur is one of the most abundant and inexpensive elements available.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conducting carbon materials (graphene, CNTs) are used to achieve electrical and thermal conductivity, then hybrid composite properties are enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical and thermal conductivityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the conductivity mechanism parameter from relying on complex carbon nanotube or graphene networks to utilizing sulfur's intrinsic redox-based electrical conductivity. Sulfur provides adequate electrical conductivity for supercapacitor applications through its multiple oxidation states, eliminating the need for complex conducting carbon material processing and assembly.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts the essential functionality (electrical conductivity for energy storage) from the complex carbon material systems and implements it through simpler sulfur-based redox reactions. This extraction approach removes the manufacturing complexity associated with handling and processing carbon nanotubes or graphene while retaining the core electrochemical functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

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 LDPE-sulfur hybrid composite demonstrates improved thermal stability, mechanical properties, and mercury adsorption capacity, with potential for high-performance energy storage applications in supercapacitors, overcoming the limitations of previous materials.

Implementation Method 1

Multiple oxidation states of sulfur (+6, 5, 4, 3, 2, 1, −1 and −2) are useful for reversible redox response for energy storage

Methodology Applied

Scientific EffectRedox reactions: Redox Reactions

Implementation Method 2

elemental sulfur substantially uniformly dispersed in the polymer matrix

Methodology Applied

Scientific EffectDispersion: Dispersion (of waves)

Data Source

PatentUS20230416511A1Low-density polyethylene/elemental sulfur hybrid composite electrode material for supercapacitors

Publication Date: 2023.12.28 KHALIFA UNIV OF SCI & TECH

AI summary

Embodiments of the present disclosure describe a hybrid composite material comprising a polymer matrix and elemental sulfur substantially uniformly dispersed in the polymer matrix, wherein the polymer is a branched polymer. Electrochemical devices, which may be fabricated from the hybrid composite material, adsorbents comprising the hybrid composite materials, and methods of using the devices and adsorbents are also provided.