Micromachined Separator for Super-Capacitor Ion Transmission
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Solution Overview
Problem
The miniaturization of portable electronic devices is hindered by increasing energy requirements, and conventional super-capacitors face issues with electrode short circuits due to insulative separators that are not permeable to ions, limiting their effectiveness in energy storage.
Innovation Solution
A method of producing super-capacitors using a robust separator with micromachined holes that allow ion transmission, formed from materials like nitride or parylene, and wafer bonding to create a chamber with out-of-plane electrodes and electrolyte, preventing electrical contact while enabling ion movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust insulative separator is used between electrodes, then electrical contact between electrodes is prevented, but ion transmission is blocked limiting energy storage effectiveness
Solution Approach 1:
The separator is designed with micromachined holes penetrating through its thickness, transforming it from a solid impermeable structure to a porous one. These holes have dimensions (e.g., 2 nanometers to 5 microns) that permit ion transmission while the separator material itself maintains electrical insulation properties, thus resolving the contradiction between preventing short circuits and allowing ion flow.
Solution Approach 2:
The separator combines two key properties: electrical insulation from materials like nitride or parylene, and ion permeability through micromachined holes. This composite structure integrates the beneficial properties of insulative materials with the transport capability of porous structures, enabling simultaneous achievement of electrical isolation and ionic conduction.
2Reliability
If separator material is made substantially impermeable to ions, then electrical insulation is enhanced, but ion movement is restricted reducing super-capacitor performance
Solution Approach 1:
The separator is segmented into solid insulative regions and hollow hole regions. The solid portions provide electrical insulation while the hollow holes provide ion transport pathways. This segmentation allows the separator to perform both functions simultaneously without compromise.
Solution Approach 2:
Different regions of the separator have different properties: the bulk material provides electrical insulation while the micromachined holes provide ion permeability. This local differentiation of properties allows the separator to satisfy both electrical insulation and ion transmission requirements in different locations of the same component.
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 enhances the energy storage capacity and reliability of super-capacitors by allowing free ion movement through the separator, addressing the limitations of prior art separators and enabling efficient energy storage in compact devices.
Implementation Method 1
The holes are sized to permit transmission of the ions of the electrolyte through the holes
Implementation Method 2
wafer bond the first substrate to the second substrate
Data Source
AI summary
A method of producing a super-capacitor provides a first substrate having a first base, forms a first electrode on the first substrate, and forms a separator so that the electrode is between the first base and the first separator. The method also micromachines holes through the separator, forms a chamber, and adds electrolyte, having ions, to the chamber. The electrolyte is in contact with the first electrode within the chamber. In addition, the holes are sized to permit transmission of the ions of the electrolyte through the holes.