Reflow-Resistant EDLC Storage Cell for Compact PCB Power
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Solution Overview
Problem
Conventional ultracapacitors are too large for compact designs, vulnerable to the reflow process used in electrical circuit assembly, and have limited lifetimes, making them unsuitable for compact, high-power applications on printed circuit boards.
Innovation Solution
A compact ultracapacitor design featuring a sealed housing with electric double layer capacitor (EDLC) technology, using carbonaceous materials and an ionic liquid electrolyte, with corrosion prevention features and a hermetically sealed envelope to withstand reflow processing and extend operational life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional ultracapacitor design is used, then high power output is achieved, but device size becomes too large for compact designs
Solution Approach 1:
The patent changes the chemical parameters of the electrolyte by using an ionic liquid instead of conventional aqueous or organic electrolytes. This parameter change enables higher operating voltages (up to 3.0V or higher) which directly increases power output while the compact cell design maintains small form factor, thus resolving the contradiction between high power output and compact size
Solution Approach 2:
The patent employs composite electrode structures combining multiple materials (such as activated carbon, carbon nanotubes, and metal oxides) to achieve high capacitance density in a compact volume. This composite approach allows the ultracapacitor to deliver high power output from a small size, resolving the contradiction between power output and device size
2Power
If conventional ultracapacitor is used, then high power delivery is achieved, but vulnerability to reflow process increases
Solution Approach 1:
The patent uses an ionic liquid electrolyte that creates a chemically inert environment within the cell, protecting the electrodes and internal components from degradation during the reflow soldering process. The ionic liquid's stability at high temperatures prevents harmful chemical reactions, allowing the ultracapacitor to withstand reflow processing while maintaining high power delivery capability
Solution Approach 2:
The patent employs a hermetically sealed encapsulation structure with protective coatings and films that shield the internal components from thermal stress and mechanical stress during reflow processing. This protective barrier allows the device to maintain its high power delivery capability while becoming resistant to the reflow process
3Volume of moving object
If conventional ultracapacitor technology is used, then compact design is achieved, but operational lifetime is limited
Solution Approach 1:
The patent changes the operating voltage parameter to higher levels (3.0V or higher) enabled by the ionic liquid electrolyte, which increases energy storage capacity (E=0.5CV²) and thus extends operational lifetime. The compact design is maintained through efficient cell construction, resolving the contradiction between compact size and operational lifetime
Solution Approach 2:
The patent employs highly stable ionic liquid electrolyte and robust electrode materials that resist degradation over time, effectively creating a long-lasting ultracapacitor. The chemical stability of these materials prevents electrolyte decomposition and electrode degradation, extending operational lifetime while maintaining compact form factor
4Power
If conventional ultracapacitor is used, then high power output is achieved, but susceptibility to heat degradation increases
Solution Approach 1:
The ionic liquid electrolyte creates a thermally stable, chemically inert environment that protects the electrodes from heat-induced degradation. This inert atmosphere prevents oxidation and other harmful thermal reactions, allowing the ultracapacitor to maintain high power output capability while becoming resistant to heat degradation
Solution Approach 2:
The patent raises the operating temperature parameter threshold by using materials and electrolytes stable at elevated temperatures. This parameter change allows the device to operate at higher temperatures without degradation, maintaining high power output while becoming resistant to heat-related harmful effects
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 solution provides a compact, high-power ultracapacitor with extended operational life and improved durability, capable of withstanding reflow processes and maintaining performance under high temperatures and voltage, suitable for compact electronic designs.
Implementation Method 1
electric double layer capacitor (EDLC) energy storage cell is disposed within a cavity in the body including a stack of alternating electrode layers and electrically insulating separator layers
Implementation Method 2
An electrolyte is disposed within the cavity and wets the electrode layers
Data Source
AI summary
An energy storage apparatus for mounting on a printed circuit board using a solder reflow process includes: a sealed housing body including a positive internal contact and a negative internal contact disposed within the body and in electrical communication with respective external contacts. An electric double layer capacitor energy storage cell is disposed within the body Methods of manufacture are disclosed.