Porous Capacitor Electrode Conduits for Better Electrolyte Flow
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Solution Overview
Problem
Capacitors with increased anode surface area through fused powder particles struggle to achieve both high capacitance and a desirable delivered to stored energy ratio due to resistance from narrow, tortuous pores, which limits the movement of electrolyte.
Innovation Solution
The formation of conduits within the active layer of the anode, with an average width 2-20 times that of the pores, allows for easier electrolyte flow by providing a larger pathway from the surface to deeper pores, reducing resistance and enhancing the delivered to stored energy ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the anode surface area is increased by using fused powder particles with pores, then capacitance is improved, but the delivered to stored energy ratio deteriorates due to narrow and tortuous pores resisting electrolyte flow
Solution Approach 1:
The anode structure is segmented into two distinct pore systems: micro-pores (5-50 nm) within fused powder particles for high surface area and capacitance, and macro-conduits (1-100 μm) extending from surface to substrate for efficient electrolyte transport. This segmentation allows each pore type to specialize in its optimal function without compromising the other.
Solution Approach 2:
The macro-conduits act as intermediary channels that mediate between the external electrolyte reservoir and the internal micro-pore network. These conduits reduce the transport resistance that would otherwise exist in a purely micro-porous structure, enabling efficient electrolyte access to deep-embedded high-surface-area regions.
2Area of stationary object
If narrow pores are used to increase surface area, then capacitance is improved, but electrolyte movement becomes difficult reducing electrical porosity
Solution Approach 1:
The invention transitions from a single-scale pore system to a multi-scale hierarchical structure by introducing macro-conduits (micrometer scale) that connect to micro-pores (nanometer scale). This dimensional transition allows electrolyte to navigate through large channels to reach small high-surface-area pores, combining the advantages of both scales.
Solution Approach 2:
The micro-porous particle structure is nested within a larger macro-conduit framework. Multiple micro-pores are accessible through and nested within the hierarchy of larger conduits, creating a nested pore architecture where smaller high-surface-area structures are embedded within larger transport pathways.
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 approach increases the capacitance while improving the electrical porosity, enabling a delivered to stored energy ratio greater than 0.90:1, which is beneficial for applications like Implantable Cardioverter Defibrillators by reducing the amount of stored energy needed for the same output.
Implementation Method 1
The formation of the conduits causes a portion of the dielectric to convert from a first phase to a second phase
Data Source
AI summary
Fabricating a capacitor includes forming conduits in a porous layer of material. The porous layer of material has particles that each includes a dielectric on a core. The formation of the conduits causes a portion of the dielectric to convert from a first phase to a second phase. The method also includes removing at least a portion of the second phase of the dielectric from the porous layer of material.