Nanostructured Electrode With Aluminum Carbide for Low-ESR CNT Transfer
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Solution Overview
Problem
Effective transfer of carbon nanotubes onto a current collector for capacitors has proven challenging, affecting performance capabilities such as power density, energy density, equivalent series resistance, frequency response, and stability, with existing bonding layers increasing ESR and decreasing energy density.
Innovation Solution
The use of an aluminum current collector with an aluminum carbide layer on which carbon nanotubes are disposed, employing various alignment and compression methods, and utilizing dry or wet transfer techniques to create high-performance electrodes.
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 decreases
Solution Approach 1:
The patent removes the bonding layer from the electrode structure entirely. CNTs are transferred directly onto the current collector surface without any intermediate bonding layer, eliminating the source of increased ESR and energy density loss while maintaining adhesion through direct contact between CNTs and the current collector
Solution Approach 2:
The patent creates an asymmetric interface where the current collector surface is specifically prepared (e.g., through plasma treatment or surface roughening) to provide direct adhesion sites for CNTs, eliminating the need for a symmetric bonding layer structure that was traditionally used on both sides of the CNT interface
2Reliability
If a bonding layer is used to cause CNTs to adhere to the current collector, then adhesion is improved, but energy density decreases
Solution Approach 1:
The bonding layer is completely removed from the electrode structure. CNTs are transferred directly onto the current collector without any intermediate material, eliminating the volume occupied by the bonding layer and maximizing the proportion of active CNT material that stores energy
Solution Approach 2:
The patent changes the surface properties of the current collector (e.g., through plasma treatment, oxidation, or roughening) to increase surface area and create direct adhesion sites, allowing CNTs to bond directly without requiring an additional bonding layer that would reduce energy density
3Ease of manufacture
If CNTs are transferred onto a current collector, then electrode formation is achieved, but transfer efficiency is low
Solution Approach 1:
CNTs are pre-assembled into organized structures (such as aligned arrays or compressed mats) on a temporary substrate before transfer. This preliminary organization ensures high-density, uniform deposition onto the current collector in a single step, improving both transfer efficiency and production rate
Solution Approach 2:
A temporary substrate or transfer tape is used as an intermediary carrier for CNTs. CNTs are first assembled on this intermediate surface where conditions are optimized for CNT organization, then transferred en masse to the current collector, enabling high-efficiency production without direct manual placement
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 resulting electrodes exhibit improved performance in terms of gravimetric and volumetric power/energy density, reduced ESR, and enhanced frequency response, while maintaining stability and cost-effectiveness.
Implementation Method 1
an aluminum carbide layer on which carbon nanotubes are disposed
Implementation Method 2
aluminum carbide layer on which carbon nanotubes are 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.