Ultra Capacitor Electrode Tab Optimization for Low Resistance
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Solution Overview
Problem
Ultra capacitors face challenges in achieving low-resistance due to the relationship between the gaps and number of lead tabs relative to the electrode plate length, leading to increased resistance and potential mutual interference.
Innovation Solution
The design involves overlapping electrode lead tabs and optimizing the length, number, and gap between them according to specific equations, along with forming the electrode plates with a current collector and active layer thickness ratio within a defined range to minimize resistance and ensure efficient current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of lead tabs is increased to secure current flow path, then resistance decreases, but mutual interference between lead tabs occurs causing resistance to increase
Solution Approach 1:
The electrode plate is divided into multiple segments with lead tabs distributed across different locations. Instead of using a single large lead tab or few tabs, the electrode plate surface is segmented into multiple connection points, allowing current to flow through multiple parallel paths without causing mutual interference between tabs.
Solution Approach 2:
The lead tabs are arranged in a two-dimensional distribution pattern on the electrode plate surface rather than concentrating them in one location. By utilizing the dimensional space of the electrode plate surface, multiple tabs can be positioned at optimal locations to ensure current flow paths do not intersect or interfere with each other.
2Reliability
If the gap between lead tabs is reduced to increase current flow paths, then resistance decreases, but manufacturing precision requirements increase
Solution Approach 1:
The invention optimizes the gap distance between lead tabs by establishing specific parameter ranges. Through mathematical modeling and empirical data, the patent determines the optimal gap dimensions that balance resistance reduction with manufacturability, ensuring tabs are close enough to provide multiple current paths but far enough to avoid interference and maintain manufacturing tolerance.
3Reliability
If the length of electrode plate is increased to accommodate more lead tabs, then resistance decreases, but device volume increases
Solution Approach 1:
The lead tabs serve multiple functions: they are both the connection points for external circuits and the structural elements that define the electrode plate segmentation. By making the lead tabs multi-functional, the invention reduces the need for additional components or extended electrode plate dimensions, thereby maintaining compact device volume while achieving low resistance through optimized tab arrangement.
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 configuration ensures a low-resistance ultra capacitor with reduced heat generation and improved energy efficiency by optimizing the electrode plate dimensions and lead tab arrangement, alleviating mutual interference and enhancing current flow paths.
Implementation Method 1
at least one separator disposed between the first electrode and the second electrode to electrically insulate the first electrode and the second electrode
Implementation Method 2
the plurality of first electrode lead tabs overlapping each other and the plurality of second electrode lead tabs overlapping each other
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5
AI summary
A low-resistance ultra capacitor capable of implementing low-resistance according to one aspect of the present invention comprises a bare cell (200) comprising: a first electrode (210) having a first electrode plate (212) and a plurality of first electrode lead tabs (214) connected to the first electrode plate (212); and a second electrode (220) having a second electrode plate (222) and a plurality of second electrode lead tabs (224) connected to the second electrode plate (222). The length of the first electrode plate (212) or the second electrode plate (222), the number of the first electrode lead tabs (214) or the second electrode lead tabs (224), and the gap between the first electrode lead tabs (214) or the second electrode lead tabs (224) are defined by a formula, 0.8 < (W × QLT) / L < 1, wherein W is the gap between the first electrode lead tabs (214) or the second electrode lead tabs (224), QLT is the number of the first electrode lead tabs (214) or the second electrode lead tabs (224), and L is the length of the first electrode plate (212) or the second electrode plate (222).