FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION: Zigzag Ultracapacitor / Development of Zigzag structured
Ultracapacitor
2. APPLICANT(S)
l.(a)NAME:Shailendra
(b) NATIONALITY: Indian
(c) ADDRESS: C/O Bacchu Lal Verma
Room No. 1, Azad Nagar
ChawlNo. 18/B,
Meghwadi,
Near Pal Kirana Store, Jogeshwan (East), Mumbai- 400060 Maharastra, India
Ph No. 9221959677
2. (a) NAME: Akanksha Dixit
(b) NATIONALITY: Indian
(c) ADDRESS: C/O Kuldeep Shukia
SAI Care Centre,
13-14 First Floor,
Vimal Chandra Jain Complex
NH-2, Jain Nagar
Firozabad-283203
Uttar Pradesh, India
3. PREAMBLE TO THE DESCRIPTION
COMPLETE The following specification particularly describes the invention and the manner in which is to be performed.
4. DESCRIPTION (Description shall start from next stage.)
5. CLAIMS (Not applicable for provisional specification. Claims should start with the preamble
- "I/We claim" on separate page)
6. DATE AND SIGNATURE (to be given at the end of last page of specification).
7. ABSTRACT OF THE INVENTION (to be given along with complete specification on
separate page)
Note:-
*Repeat boxes in case of more than one entry.
*To be signed by the appHcant(s) or by authorized registered patent agent
*Name of the applicant should be given in full, family name in the beginning.
*Complete address of the applicant should be given stating the postal index no./code, state
and country.
*Strike out the column(s) which is/are not applicable.

DATA REQUIRED FROM THE PROSPECTIVE PATENT APPLICANT
I. Data required for drafting the Patent Specification.
1. TITLE OF YOUR INVENTION -Zigzag Ultracapacitor
Development of Zigzag Structured Ultracapacitor
2 FIELD OF INVENTON
The present invention proposes a new structure of ultracapacitor, called as zigzag structure. This structure delivers promising results for capacitance, peak current values, equivalent series resistance, energy density and power density.
3 PRIOR ART
Ultracapacitor is the latest and efficient energy storage device that undergoes frequent charge and discharge cycles at high current and short duration. It gives the highest available capacitance values per unit volume and highest energy density of all capacitors. Based on the methods of construction, different types of ultracapacitors are manufactured and used in many small and large scale applications. The basic structures of ultracapacitor which are used are the stacked type structure, rolled type, flexible etc. Although these structures are used for different purposes but they suffer a few drawbacks. The stacked type structure gives high value of capacitance but it is useful only in low power consumption for example provide starting power in start-stop systems and help power electrical systems, starter systems and power steering in hybrid and electric cars. When more units of stacked type ultracapacitor are packed together in parallel to get high peak current and high capacitance value its packing efficiency decreases due to the formation of air bubbles. Due to parallel connection of large number of units, the circuitry becomes complex and also the chances of circuit damage are increased.
Considering the rolled type structure, most of the problems of the stack type structure are sorted out to some extent but the major problem with the rolled type structure is less penetration of electrolyte within the structure. As a result the accumulation of charge carriers within the electrodes reduces. Hence the charge density of this structure is low as per the requirement. Also the rolled type model suffers a drawback on flexibility ground. The rolled type model is not at all flexible. Therefore, a special type of structure is needed which gives the advantage of these models of ultracapacitors. In the proposed invention, these problems are addressed.
4 OBJECTIVE OF THE INVENTION:
Zig-Zag model of ultracapacitor is proposed in the invention. Zig-zag model capacitors has been tried with limited success but in the present invention the idea of zig-zag model is extended to the ultracapacitors. In the said invention the zig-zag structure has been implemented in ultracapacitors which hold the novelty of the invention. The basic idea behind the proposed zigzag structure is to increase the area in contact of the electrolyte with the electrode and the penetration of electrolyte across the separator membrane becomes easy. Due to this, the ionic mobility across the separator pieces increases. This increases the charge accumulation within the electrodes. This in turn increases the pulse peak current, capacitance and the charge density which is essential for large scale application since high value of surge current and capacitance is required in this field. Thus this invention aims at developing an ultracapacitor prototype which finds applications in demanding situations overcoming the drawbacks of the present models of ultracapacitor.
1. Objective of the present invention is to provide one piece of ultracapacitor with high value of peak current and capacitance using the zig-zag prototype convention which was

earlier tried with the capacitor technology with a little success. This extension to the ultracapacitor family is unique
2. Another objective of the present invention is to develop one piece ultracapacitor which can be used m various applications requiring high pulse current.
3. Another objective of the present invention is to provide ultracapacitor with lower internal resistance compared to prior art ultracapacitors.
4. Another objective of the present invention is to reduce manufacturing cost by using low cost separator pieces, current collector i.e wire mesh, activated carbon and metal oxide.
5. Another objective of the present invention is to provide ultracapacitor which provides
electrolyte penetration to a much greater extent compared to rolled type ultracapacitor.
6. Yet another objective of the present invention is to provide an ultracapacitor which is binder free which is usually mixed in electrode material to provide binding effect between the electrode and electrode material and hence less expensive as compared to those capacitors which employ the use of expensive binders.
7. Yet another objective of the present invention is to provide ultracapacitor with lesser number of air pockets between separator pieces and electrodes as compared to the rolled type ultracapacitors.
8. Yet another objective of the present invention is to obviate need of expensive and time consuming process required for using carbon nano tubes, which makes the capacitor expensive. To achieve the objectives mentioned above, the present invention makes use of a fine wire mesh of corrosion resistant metal. It is preferred to use the said wire mesh having at least 1000 holes per square inch. Said wire mesh is provided with electrical connections. The wire mesh is loaded with activated carbon having specific surface area more than 250 square meters per gram along with any one heavy (transition) metal oxide from the group consisting of ruthenium oxide, manganese oxide, vanadium oxide and stannic oxide. Said metal oxide is added to said activated carbon. The proportion of activated carbon: metal oxide is preferred in the ratio of at least 20:1 weight by weight. Amount of loading of this electrode material is to be kept at least of 10mg/ square cm. This mixture is mechanically crushed and then isopropyf alcohol solution is added in it to make slurry with non flowing consistency under gravity. Said mixture is then mixed using ultrasonic ultrasound mixing process, exposing the same to ultrasound for at least 1 hour.
Said slurry is applied on said wire mesh on its active surface area leaving the terminals for electrical connections. The electrode thus coated is dried with flow of warm air taking care not to disturb the slurry applied on it, while applying the slurry.
One more electrode is prepared by repeating above mentioned procedure. Two electrodes are placed on opposite sides of separator piece. Said separator piece is preferably a sheet of acid resistant material having porosity of at least 60 %. The size of said sheet is kept in excess of the size of said wire mesh. An acid resistance adhesive is then pasted on both sides of the separator piece such a way that this adhesive will come exactly on four edges of each wire mesh electrodes prepared, once they are placed on the separator piece on two sides. Two more separator pieces of same size and material are then placed from both sides of said two electrodes in such a way that one separator piece is there between two electrodes as said earlier. This forms a sandwich type of structure consisting of three separator pieces and two loaded electrodes. The adhesive is also applied on two longer outer edges of both the sides of this structure. A part of the said structure is folded firstly 3 80° in forward direction and then remaining part is folded 180° in backward direction repeatedly in such a manner that it forms zigzag shape. The adhesive pasted at all the outer edges help to bind the ultracapacitor assembly as a whole unit in a zig-zag manner. The ultracapacitor so prepared is then sandwiched between two jaws of hand press and applied with pressure of at least 5 kg per sq cm for a period sufficient for drying of adhesive.

The ultracapacitor, so prepared is then immersed in an ionic solution having strength of at least
0.65 molar which acts as an electrolyte for more than 2 hours. Said ultracapacitor is now ready for
use. It can also be used in any electrolyte having similar properties as that of said ionic solution.
With above described process, according to present invention binder material is obviated as two
electrodes with current collector are packed between two separator sheets and third separator
sheet is held between two electrodes.
Adhesive around the four edges of the electrode prevents leakage of electrode material away from
wire mesh. The pressure applied in the process eliminates possibility of forming air pockets
between separator piece and electrode.
Thus according to the method of the present invention all the objectives mentioned above are
achieved.
5 STATEMENT OF INVENTION:
Method of manufacturing electrode for ultracapacitor comprising steps of
a) Loading a wire mesh of corrosion resistant metal with a mixture of activated carbon, a metal oxide and an organic solvent like isopropyl alcohol forming a slurry; said mixture being mixed thoroughly; said wire mesh provided with extension without said loading enabling electrical connection to said wire mesh, said wire mesh having at least 1000 holes per square inch.
b) Drying said loaded wire mesh by blowing warm air over it without disturbing the loaded mixture.
c) Preparing one more electrode as described in procedure (a) and (b) and keeping dried wire mesh electrodes on two sides of a sheet of separator material, said separator material being resistant to acid and having porosity, size of said sheet being excess of the size of said wire mesh.

d) An acid resistant adhesive pasted on said sheet covering all edges on both sides of said wire meshes.
e) Placing two more sheets of separator materia! over the adhesive to cover said two wire meshes from both sides
fj The adhesive is also applied on two longer outer edges of both the sides of this structure. A part of
the said structure is folded firstly 180° in forward direction and then remaining part is folded 180° in
backward direction repeatedly in such a manner that it forms zigzag shape. The said zig-zag
prototype has been tried with capacitors but with a little success and now this idea is further
used in ultracapacitors in the proposed invention. The adhesive pasted at all the outer edges help to
bind the ultracapacitor assembly as a whole unit in a zig-zag manner.
g) Applying pressure of at least 5kg per square centimetre over it, till said adhesive is completely
dried; thereby forming a single ultra capacitor assembly.
h) Soaking said ultra capacitor assembly in ionic solution, said solution being used as an electrolyte in
ultra capacitor wherein said ultra capacitor is to be used.
Method of manufacturing ultra capacitor wherein proportion of said activated carbon to said metal oxide is at least 20:1.
Said activated carbon having surface area of at least 250 square meters per gram;
said sheet of separator material has at least 60% porosity and maximum pore size 20 microns;
said acid having strength of at least 5%;
said material of the sheet of separator having capacity to withstand attack of said acid of at least 5% strength.
6 DESCRIPTION OF FIGURES :

Fig 3 shows wire mesh used to make the electrode according to present invention
Fig 2 shows wire mesh loaded with electrode material according to present invention
Fig 3 shows compietely loaded wire mesh with electrode material according to present invention
Fig 4 shows sectional front view of ultracapacitor loaded wire mesh inserted between two seperator
pieces according to present invention
Fig 5 shows sectional view of ultracapacitor with five layers (three separator pieces and two loaded
wire meshes, it can be 1,2,3,4 and 5 layers) of ultracapacitor according to present invention
Fig 6 shows the perspective view of ultracapacitor folded in zigzag structure according to present
invention
Fig 7 shows the compressed form of zigzag structured ultracapacitor according to present invention.
Fig 8 shows the three dimensional view of final version of zigzag structured ultracapacitor according
to present invention
Fig 9 shows sectional view of zig2ag structured ultracapacitor dipped in electrolyte according to
present invention.
7. DESCRIPTION OF INVENTION
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention as described below, in the preferred embodiment.
This invention is illustrated in the accompanying drawings, throughout which, like reference letters indicate corresponding parts in the various figures.
The present invention proposes to use the zig-zag style of formation for ultracapacitor which was earlier tried with the capacitors with a low success rate. This technology provides zig-zag type of ultracapacitor with two electrodes and three separator pieces gets sandwiched to form zig-zag type ultracapacitor. Said zig-zag type of ultracapacitor comprising of two metallic wire meshes of corrosion resistant metal and three sheets of separator. It is preferred to use the said wire mesh having at {east 1000 holes per square inch (20). An extension provided on each wire mesh as an electrical connection enabling connection of the electrode to outside devices (10). Both wire mesh (fig 1) are loaded with a mixture made of an activated carbon having surface area more than 250 square meters per gram along with any one heavy (transition) metal oxide from the group consisting of ruthenium oxide, manganese oxide, vanadium oxide and stannic oxide. Said metal oxide is added to activated carbon. The proportion of activated carbon: metal oxide is preferred in the ratio of at least 20:1 weight by weight. Amount of loading of this electrode material is to be-kept at least of lOmg/ square cm. This mixture is mechanically crushed and then isopropyl alcohol solution is added in it to make slurry with non flowing consistency under gravity. Said mixture is then mixed using ultrasonic mixing process, exposing the same to ultrasound for at least 1 hour.
Said slurry is applied on said both wire meshes on its active surface area (30) leaving the terminals for electrical connections (10). Both wire meshes thus coated is dried with flow of warm air taking care not to disturb the slurry applied on it, while applying the slurry.
Said wire mesh (6) is then put on first sheet of separator material (3); herein after referred to as "the first sheet" Said separator materia! is preferably an acid resistant material having porosity of at least 60 % and maximum pore size being 20 micros. The size of said first sheet is kept in excess of the size of said wire mesh so as to cover it completely on its edges (4) and (5). An acid resistance adhesive is then pasted on the first sheet in such a way that this adhesive will cover all edges of the wire mesh (fig 2)-
A second sheet of the separator material is then placed over the wire mesh to cover it completely (fig 4) and one more electrode prepared by described procedure is placed on a second sheet of the ultracapacitor. An acid resistance adhesive is then pasted on the other side of second sheet in such a

way that this adhesive will cover ali edges of the wire mesh of second electrode. On the second electrode one more i.e. third separator sheet is placed. Size of first sheet(l), second sheet (3) and third sheet (5) is kept same. This forms a sandwich type of structure consisting of three separator pieces and two loaded electrodes (2) and (4). The adhesive is also applied on two longer outer edges of both the sides of this structure(6). A part of the said structure is folded firstly 180° in forward direction and then remaining part is folded 180° in backward direction repeatedly in such a manner that it forms zigzag shape ( fig 6). The adhesive pasted at all the outer edges help to bind the ultracapacitor assembly as a whole unit in a zig-zag manner. Then the combined zig-zag ultracapacitor structure is applied with pressure of at least 5 kg per square cm for a period sufficient for drying of said adhesive up to a temperature that does not affect the porosity of the separator of said adhesive( fig 7). The zig¬zag type of ultracapacitor so prepared ( fig 8) is then immersed and soaked in an ionic solution, having strength of at least 0.65 molar which acts as an electrolyte, for more than 2 hours( ftg 9). The material of separator sheet (15) is so selected that, it sustains the attack of said electrolyte used for immersion and as an electrolyte without degradation. Said zig-zag type of ultracapacitor is now ready for use as an ultracapacitor.
Method of use of said zig-zag type of ultracapacitor described below.
A container (13) made of chemical resistant material so as to sustain attack of electrolyte( 12) used is filled completely with the ionic solution and fixed with a cover(16) in sealable manner. Plurality of zig-zag type of ultracapacitor is immersed in ionic solution which is acting as electrolyte in such a way that, said electrical connections extend out from cover.
Said extended electrical connections(ll) of any two electrodes are used as electrical terminals to connect electrical load across the ultracapacitor to achieve required capacitance.
With above process according to present invention binder material which is usually mixed in
electrode material to provide binding effect between the electrode and electrode material is obviated
as the activated carbon and metal oxide mixture loaded electrodes are packed in between separator
sheets.
Adhesive around the four edges of the electrode prevents leakage of electrode material away from
wire mesh. The pressure applied in the process eliminates possibility of forming air pockets between
separator piece and electrode.
Thus according to the method of the present invention all the objectives mentioned above are
achieved.
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment.
Detailed descriptions of the preferred embodiment are provided herein, however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or matter.
The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention; which is defined by the scope of the following claims.
The steps of construction of zigzag structure ultracapacitor is described using flow chart as
follows:

Cut two electrodes of stainless steel of required surface area
<>
Take mixture of activated carbon and transition metal oxide
such as manganese dioxide, vanadium pentaoxide, lead oxide
etc. in 1:1 weight ratio
<>
Crush it manually and prepare slurry using solvent

Keep the mixture for ultrasonic mixing to maintain uniformity in macroscopic as well as microscopic level
<>
Load the slurry on the electrode uniformly using doctor blade and allow it to get dry up
These two electrode then sandwiched between two alternative
separator pieces separated by one more separator piece. Paste it
using epoxy resin as an adhesive
<>
Keep it for minimum 6 hour to get solidify under heavy pressure to reduce number of air pockets
<>
Dip this solid electrode in any electrolyte for 2-5 hours and subject it to 10-30 charge-discharge cycles
<>
Now, it is ready for use

ADVANTAGES OF THE INVENTION:
(a) The proposed prototype of ultracapacitor gives significant value of peak current and
capacitance.
(b) It also overcomes the problem of electrolyte penetration which persists in the rolled type structure providing better eiectrode-electroiyte interaction than in the other prototypes.
(c) It can be easily used where high faradic value is required due to presence of lesser number of air pockets.
(d) The present invention provides ultracapacitor with lower internal resistance compared to prior art ultracapacitors of other type of structures.
(e) Also the packing efficiency of zigzag type ultracapacitor is more than the other prototypes due to decrease in air gap.
(f) The flexibility constraints are also relaxed in zigzag structure. This model is more flexible
to the demands of industry due to its versatile nature as compared to the other models under
development today and hence it can be used in film based technology of ultracapacitor.

WE CLAIM:
1. Method of manufacturing electrodes for zig-zag ultra capacitor which is an extension of the zig-zag convention from capacitors to uttracapacitors comprises steps of
(a) loading a wire mesh of corrosion resistant metal with a mixture of activated carbon, a
suitable metal oxide and organic solvent like isopropyl alcohol forming a slurry; said mixture
being mixed thoroughly; said wire mesh provided with extension without said loading enabling
electrical connection to said wire mesh; said wire mesh having at least 1000 holes per square
inch;
(b) drying said loaded wire mesh by blowing warm air over it without disturbing the loaded mixture:
(c) keeping dried wire mesh on a sheet of separator material, said separator material being resistant to acid and having porosity, size of said sheet being excess of the size of said wire mesh;
pasting an acid resistant adhesive pasted on said sheet covering all edges of said wire mesh,
(d) placing a second sheet of separator material over the adhesive to cover said wire mesh and the adhesive pasted
(e) Placing the second electrode prepared on the second sheet of electrode in opposite direction and placing third sheet of separator on second electrode pasting an acid resistant adhesive pasted on said sheet covering all edges of said wire mesh.
(f) Folding this structure in such a manner that it forms zigzag shape i.e. firstly folding in forward direction and then backward direction repeatedly
(g) applying pressure of at least 5kg per square centimeter over it, till said adhesive is completely dried; thereby forming an ; a final structure of zigzag type ultracapacitor
(h) soaking the said ultracapacitor in an ionic solution of said electrolyte
2. Method of manufacturing zig-zag type of ultracapacitor as claimed in claim 1 wherein
proportion of said activated carbon to said metal oxide is at least 20:1;
said activated carbon has surface area of at least 250 square meters per gram;
said sheet of separator material has at least 60% porosity and maximum pore size 20 microns:
said electrolyte having strength of at least 0.65 molar
said material of said separator sheet having capacity to withstand attack of said acid of at least
5% strength.
3.Method of manufacturing electrode for ultracapacitor as claimed in claim 1 wherein said
mixture is mixed by ultrasonic process.
4. Method of manufacturing electrode for ultracapacitor as claimed in claim 1 wherein
said soaking in ionic electrolyte is done for at least 2 hours.
5. Method of manufacturing electrode for ultracapacitor as claimed in claim 1 wherein metal
oxide is selected any one from the group consisting of, ruthenium oxide, manganese oxide,
vanadium oxide and stannic oxide or any oxide that sustain low conductivity and is chemically
stable.
6. Method of manufacturing electrode for ultracapacitor as claimed in claim 1 wherein said pressure is applied up to a temperature that does not affect the porosity of the separator of said adhesive.
7. Method of using said zig-zag type of ultracapacitor is as follows:

1. filling a container made of chemical resistant material with ionic electrolyte;
2. fixing a cover to said container in sealable manner;
3. plurality of said zig-zag type of ultracapacitor is immersed in said electrolyte in such a way that, said electrical connections extend out from cover: connecting electrical load between said extended electrical connections of any two electrodes for using the ultracapacitor of reouired value.
8. Method of manufacturing electrode for ultracapacitor as claimed in claim 1 to 7 as
substantially described hereinbefore, with reference to the accompanying drawings.