Wound Capacitor Multi-Point Edge Connections
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Solution Overview
Problem
Conventional capacitors have high resistance due to limited electrical connections, leading to increased heat generation during charge and discharge, which accelerates degradation and reduces their performance.
Innovation Solution
The capacitor design includes a wound structure with exposed parts of the electrodes connected at multiple points, reducing interconnection resistance through electrode machined parts and optimized lead connections, allowing for efficient current distribution and improved electrical connections without removing polarized electrode layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional single-point lead connections are used, then the structure is simple, but resistance is high leading to heat generation
Solution Approach 1:
The electrical connection structure is segmented into multiple connection points distributed along the collector edges, transforming a single-point connection into a multi-point parallel connection system. This segmentation reduces resistance and heat generation by distributing current flow across multiple pathways.
Solution Approach 2:
The connection structure transitions from a single-point (0D) or single-line (1D) connection to a distributed multi-point connection along the edge dimension. This dimensional expansion along the collector edge enables parallel current paths and reduces electrical resistance.
2Reliability
If polarized electrode layers are removed to expose collectors, then electrical connections are improved, but electrode integrity is compromised
Solution Approach 1:
The electrode structure implements local quality differentiation where the polarized electrode layer is removed only at specific edge regions to create connection areas, while the main body of the electrode retains its complete polarized layer structure. This localized modification improves electrical connection without compromising overall electrode integrity.
Solution Approach 2:
The polarized electrode layer is preliminarily removed at the edges before final assembly, creating pre-formed connection areas. This preliminary action ensures reliable electrical connection is established before the electrode is put into service, avoiding the need for later modifications that could compromise integrity.
3Reliability
If multiple connection points are created, then resistance is reduced, but manufacturing complexity increases
Solution Approach 1:
The electrode manufacturing process is segmented into distinct steps: forming connection areas at edges, winding with separator, and connecting leads. This segmentation allows each step to be optimized independently, making the multi-point connection process manageable and manufacturable.
Solution Approach 2:
Connection areas are preliminarily formed on collector edges before winding, allowing subsequent assembly steps to simply connect leads to these pre-prepared areas. This preliminary preparation simplifies the overall manufacturing process despite the increased number of connection points.
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 design significantly reduces resistance, enabling high-power density capacitors capable of large current charging and discharging, while maintaining flexibility in module assembly and reducing heat generation.
Implementation Method 1
positive electrode 102 and negative electrode 103 with separator 104 therebetween... polarized electrode layer 102B and 103B formed on both faces of collector 102A and 103A
Data Source
AI summary
Two electrodes are drawn out from a wound capacitor element by a pair of leads. Each of electrodes forming the capacitor element includes a sheet-like collector, an electrode layer formed on the surface of the collector, and an exposed part provided on one edge of the collector. The electrode layer is not formed on the exposed part. The electrodes are wound such that the exposed parts come to both ends of the capacitor element. Two or more points of at least one of the exposed parts are connected together.