Supercapacitor Electrolyte Filling Through a Bottom Fluid Passage

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The manufacturing of supercapacitors with microporous carbon electrodes faces challenges due to electrolyte boiling and spilling issues when filling cylindrical cans, leading to delays and inefficiencies in production.

Innovation Solution

A method involving a cell body with a bottom protrusion and exterior welding grooves, where the electrode assembly is inserted and welded, and the electrolyte is filled through a bottom fluid passage or top opening, with a lid assembly that includes a sealing member to prevent electrolyte boiling and ensure efficient sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrolyte is filled through a small opening in the lid, then the cylindrical can can be closed, but the electrolyte may boil and spill due to adsorption heat, causing manufacturing delays

Engineering Contradiction:

Improveease of electrolyte fillingVSAvoidreliability of electrolyte containment

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The filling process is segmented into multiple stages: initial electrolyte introduction through the small lid opening, followed by controlled additional filling after cooling periods. This segmentation allows heat dissipation between filling stages, preventing boil-over while maintaining the simplicity of the small opening design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing process employs periodic action through alternating filling and cooling cycles. Electrolyte is filled in intervals with cooling periods in between, allowing the system to dissipate adsorption heat before the next filling stage, thereby preventing continuous boil-over conditions.

Inventive Principle:

Principle #19Periodic action

2Productivity

If electrolyte is filled quickly to improve production rate, then manufacturing efficiency increases, but electrolyte boiling and spilling occurs more frequently

Engineering Contradiction:

Improveproduction rateVSAvoidmanufacturing delays

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

Cooling actions are performed preliminarily before subsequent electrolyte filling stages. The system prepares by cooling the electrode assembly and previously filled electrolyte before introducing more electrolyte, preventing boil-over conditions that would cause manufacturing delays.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The process incorporates beforehand cushioning by introducing cooling periods and controlled filling rates before the system reaches critical temperature levels. This cushioning approach prevents electrolyte boil-over by anticipating heat accumulation and addressing it before problems occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Speed

If the lid opening is made larger to facilitate electrolyte filling, then filling speed increases, but sealing complexity and potential leakage increase

Engineering Contradiction:

Improveelectrolyte filling speedVSAvoidlid assembly complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The small lid opening serves multiple functions: it allows electrolyte filling, maintains adequate sealing, and facilitates heat dissipation during the filling process. By making the opening serve these multiple functions, the design avoids the need for larger openings that would compromise sealing or require complex closure mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method reduces manufacturing delays and improves production rates by preventing electrolyte boiling and spilling, allowing for faster and more controlled filling of electrolyte, and enhances the sealing and thermal management of supercapacitors.

Implementation Method 1

When coming into contact with the electrode assembly, the electrolyte typically adsorbs to the micropores thereby releasing energy in the form of heat

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

closing the top opening with a lid assembly thereby forming a cell interior that contains the electrode assembly immersed in the electrolyte

Methodology Applied

Scientific EffectSealing: Physical Containment

Implementation Method 3

fixing the electrode assembly to the bottom portion in an electrically conductive manner

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20240186077A1Method for manufacturing a supercapacitor

Publication Date: 2024.06.06 SKELETON TECH GMBH

AI summary

A method for manufacturing a supercapacitor, including, integrally forming a cell body having a bottom portion, a wall portion, and a top opening, as a single unitary member, with the bottom portion having a bottom fluid passage; inserting through the top opening an electrode assembly that has a negative and positive electrodes separated by a separator; fixing the electrode assembly to the bottom portion in an electrically conductive manner; closing the top opening with a lid assembly forming a cell interior containing the electrode assembly in a dry state, and fixing the lid assembly to the cell body; orienting the cell body with the bottom fluid passage facing downward in a vertical direction; injecting an electrolyte through the bottom fluid passage to wet the electrode assembly with the electrolyte; and closing the bottom fluid passage with a plug member and fixing the plug member to the bottom portion.