Supercapacitor Solid Insulation Layers for High Voltage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional supercapacitors are limited to low voltage applications due to their low cell voltage, requiring series connection of multiple units for higher voltage applications, which increases footprint and costs, and lacks mechanical robustness and resistance to leakage currents.
Innovation Solution
A supercapacitor design featuring pinhole-free solid electrical insulation layers with a dielectric breakdown strength of at least 25 V/µm, covering the entire electrode surface, increasing cell voltage and mechanical robustness, and using a solid ion carrying medium to eliminate liquid electrolyte-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional supercapacitors are used without solid insulation layers, then the device structure is simple, but the cell voltage is limited to low values (2-3 Volts) and electrical withstand strength is insufficient
Solution Approach 1:
The patent applies thin film solid electrical insulation layers (30, 30') covering the electrode surfaces (20, 20'). These thin film barriers provide enhanced electrical withstand strength and enable higher cell voltages while maintaining a compact structure, resolving the contradiction between strength improvement and structural simplicity.
2Strength
If multiple supercapacitors are series-connected to achieve higher voltage, then the voltage requirement is met, but the footprint increases significantly
Solution Approach 1:
The patent changes the electrical parameters of the supercapacitor by introducing solid insulation layers with specific dielectric breakdown strength (at least 25 V/μm) and controlled thickness (0.5-5 μm). This enables a single cell to achieve higher voltages (at least 2.5 V per layer) without requiring series connections, thereby reducing the footprint while meeting voltage requirements.
3Reliability
If liquid electrolyte is used in supercapacitors, then ionic conduction is achieved, but leakage currents and mechanical robustness are compromised
Solution Approach 1:
The patent changes the physical state of the ion-carrying medium from liquid to solid. The solid ion-carrying medium eliminates leakage currents inherent in liquid electrolytes and provides mechanical robustness against vibrations, while maintaining ionic conduction functionality through solid-state ion transport mechanisms.
4Strength
If solid insulation layers with high dielectric breakdown strength are used, then cell voltage is increased, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies thin film insulation layers with thickness of 0.5-5 μm and dielectric breakdown strength of at least 25 V/μm. This combination allows achieving high cell voltage (at least 2.5 V per layer) while keeping the layers thin enough to minimize manufacturing tolerances and maintain cost-effectiveness.
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 enhances electrical withstand strength, allows for higher cell voltage, increased mechanical robustness, and reduces leakage currents, enabling the supercapacitor to handle higher voltage applications and withstand mechanical vibrations without the need for extensive electronics for voltage balancing.
Implementation Method 1
the material of the first solid electrical insulation layer and of the second solid electrical insulation layer has a dielectric breakdown strength of at least 25 V/μm, and wherein the thickness of the first solid electrical insulation layer and of the second solid electrical insulation layer such that the dielectric breakdown voltage of each of the first solid electrical insulation layer and the second solid electrical insulation layer is at least 2.5 volt
Implementation Method 2
an ion carrying medium configured to ionically connect the first electrode and the second electrode
Data Source
Figure 1~2
Figure 3
AI summary
The present disclosure relates to a supercapacitor (1) comprising: a first electrode (7a), a second electrode (7b), an ion carrying medium (9) configured to ionically connect the first electrode (7a) and the second electrode (7b), wherein the first electrode (7a) has a first electrode ion carrying medium facing surface (8a) and the second electrode (7b) has a second electrode ion carrying medium facing surface (8b), a first solid electrical insulation layer (7c) covering the entire first electrode ion carrying medium facing surface (8a), which thereby defines a barrier between the first electrode (7a) and the entire ion carrying medium (9), and a second solid electrical insulation layer (7d) covering the entire second electrode ion carrying medium facing surface (8b), which thereby defines a barrier between the second electrode (7b) and the entire ion carrying medium (9), wherein the material of the first solid electrical insulation layer (7c) and of the second solid electrical insulation layer (7d) has a dielectric breakdown strength of at least 25 V/µm, and wherein the thickness of the first solid electrical insulation layer (7c) and of the second solid electrical insulation layer (7d) is such that the dielectric breakdown voltage of each of the first solid electrical insulation layer (7c) and the second solid electrical insulation layer (7d) is at least 2.5 volt.