Technical Analysis of EDLC262520-501-2F-40 Electric Double-Layer Capacitor Process Characteristics

As an energy storage device bridging conventional capacitors and batteries, electric double-layer capacitors (EDLC) demonstrate significant application potential in consumer electronics, industrial equipment, and new energy sectors with their high power density, long cycle life, and rapid charge-discharge capabilities. TDK's EDLC262520-501-2F-40 model, as a typical high-performance supercapacitor, integrates the latest achievements in materials science, precision manufacturing, and electrochemical engineering. The following analysis delves into its six core process characteristics from the perspectives of technical implementation and performance optimization.

1. Multi-level Optimization of Electrode Materials
This model employs high specific surface area activated carbon as the core electrode material, utilizing nanoscale pore control technology to create complex ion adsorption channels with specific surface area exceeding 1600 m²/g. To further enhance conductivity, the electrode formulation incorporates 5% multi-layer graphene and 10% carbon black to form a composite conductive network. This three-material system (activated carbon + graphene + carbon black) balances high energy density with low internal resistance, reducing equivalent series resistance (ESR) to below 1.18Ω while enabling high-current charge-discharge capabilities.

2. Synergistic Innovation in Electrolyte Systems
Tailored for the 4.2V rated voltage requirement, the electrolyte adopts a mixed formulation of quaternary phosphonium ionic liquids and trialkyl phosphate esters. This innovative combination maintains the high conductivity advantages of ionic liquids while reducing electrolyte viscosity by 40% through the addition of trialkyl phosphate esters, shortening the injection time to 1/3 of conventional processes. Simultaneously, the hybrid electrolyte exhibits excellent wide-temperature stability (-40°C to 70°C), maintaining over 90% ionic conductivity in low-temperature environments to ensure performance under extreme conditions.

3. Precision Packaging and Structural Reinforcement
The packaging process employs metal foil laminated film technology with laser welding achieving 0.1mm-level precision sealing. The internal structure adopts a roll-back process, tightly winding electrodes and separators in a compact 26mm×20mm×2.7mm space to achieve a 500mF capacity breakthrough. Critical packaging nodes utilize corrosion-resistant nanocoatings, maintaining over 98% sealing reliability after 2000-hour salt spray tests to effectively prevent electrolyte leakage.

4. Breakthroughs in Separator Technology
Employing nanofiber-reinforced separators with optimized 68% porosity, this design ensures rapid ion migration (30% improved ionic conductivity) while preventing activated carbon particle migration through electrostatic adsorption between fibers. The 8μm-thick separator, 40% thinner than conventional products, enhances energy density while its asymmetric pore design enables selective ion permeation between positive and negative electrodes, further reducing self-discharge rates.

5. Full-cycle Quality Control System
The manufacturing process incorporates inline monitoring nodes:

Coating stage uses beta-ray thickness gauges for nanoscale coating control;
Rolling process equipped with pressure distribution sensors ensures uniform 35MPa optimal pressing pressure;
Electrolyte injection employs vacuum-pressure dual-mode systems ensuring ≥99.5% filling efficiency.
Finished products undergo five-dimensional testing matrices:
Electrical performance: Constant-current discharge method with ≤5% capacitance deviation;
Reliability: Low-temperature discharge capacity retention ≥85% at -40°C;
Lifetime: <10% capacitance degradation after 100,000 cycles;
Safety: No fire/explosion in overvoltage puncture tests;
Environmental: ROHS3 compliance + MSL1 moisture sensitivity control.
6. Application-Driven Design Innovations
For portable devices, a dual-capacitor series packaging structure maintains 4.2V rated voltage while reducing volume by 30%. The electrode tabs adopt three-dimensional folding designs, shortening current paths by 40% and enhancing high-current discharge capability to 15A. Surface-mount device (SMD) packaging with flat lead designs optimizes pin spacing to 6.25mm, meeting high-density PCB assembly requirements, particularly suitable for space-sensitive applications like smart wearables.

Conclusion
The process characteristics of EDLC262520-501-2F-40 embody three development directions of contemporary supercapacitor technology: material hybridization, structural precision, and manufacturing intelligence. Through full-chain innovations from atomic-level material design to system-level packaging, this product achieves multi-dimensional breakthroughs in energy density, power characteristics, and environmental adaptability. With the rapid development of new energy technologies and IoT devices, such high-performance EDLC devices will demonstrate greater application value in 5G base station backup power, smart sensors, and micro-robots.

Fudong Communication (Shenzhen) Group Co., Ltd., established in 2004, is a specialized global first tier semiconductor agent/distributor.

Fudong Mall is an online e-commerce platform belonging to Fudong Communication (Shenzhen) Group Co., Ltd. Fudong collaborates with global electronic component distributors and Chinese spot inventory suppliers.