Nanostructured Electrode With Carbide Interface for Low-ESR Energy Storage
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Solution Overview
Problem
Existing methods for producing electrodes with carbon nanotubes (CNTs) for energy storage devices face challenges in achieving desired performance capabilities such as power density, energy density, and equivalent series resistance (ESR), due to the use of bonding layers that increase ESR and decrease energy and power density.
Innovation Solution
The use of an aluminum current collector with an aluminum carbide layer on at least one surface, onto which CNTs are disposed, either vertically-aligned, horizontally-aligned, or non-aligned, to form a high-performance electrode for energy storage devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bonding layer is used to cause CNTs to adhere to the current collector, then adhesion is improved, but ESR increases and energy density and power density decrease
Solution Approach 1:
The patent removes the bonding layer from the electrode structure entirely. CNTs are transferred directly to the current collector surface without any intermediate bonding layer, eliminating the source of increased ESR and energy loss while maintaining adhesion through direct contact between CNTs and the current collector.
Solution Approach 2:
The patent uses a composite current collector structure consisting of a metal substrate with a metal carbide coating layer. This composite material provides both mechanical strength and surface properties that enable direct CNT adhesion without requiring an additional bonding layer, thus avoiding the drawbacks of using organic bonding materials.
2Reliability
If a bonding layer is used to cause CNTs to adhere to the current collector, then adhesion is improved, but energy density and power density decrease
Solution Approach 1:
The bonding layer is completely removed from the electrode structure. CNTs are transferred directly to the current collector without any intermediate layer, eliminating the barrier that would impede electron transport and reduce power density.
Solution Approach 2:
The metal carbide-coated current collector provides a surface with optimal properties for direct CNT adhesion, combining the mechanical strength of the metal substrate with the surface characteristics of the carbide coating that facilitate direct CNT contact and electron transport.
3Ease of manufacture
If CNTs are transferred onto a current collector, then electrode formation is achieved, but manufacturing complexity increases
Solution Approach 1:
The current collector is pre-coated with a metal carbide layer before CNT transfer. This preliminary surface preparation creates an optimal substrate for direct CNT adhesion, simplifying the subsequent CNT transfer process by eliminating the need for bonding layers and reducing manufacturing steps.
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 results in energy storage devices, such as ultracapacitors, that exhibit improved performance in terms of gravimetric and volumetric power and energy density, reduced ESR, enhanced frequency response, and increased maximum voltage.
Implementation Method 1
an aluminum carbide layer on at least one surface, on which at least one layer of CNTs is disposed
Data Source
AI summary
Disclosed herein is electrode comprising a current collector comprising a conductor layer having at least a first surface; and elongated metal carbide nanostructures extending from the first surface; and a carbonaceous energy storage media disposed on the first surface and in contact with the elongated metal carbide nanostructures. Disclosed herein too is an ultracapacitor comprising at least one electrode comprising a current collector comprising a conductor layer having at least a first surface; and elongated metal carbide nanostructures extending from the first surface; and a carbonaceous energy storage media disposed on the first surface and in contact with the elongated metal carbide nanostructures.