Surface-Modified Capacitor Electrodes to Prevent Delamination

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Solution Overview

Problem

Capacitors with high volume efficiency face challenges such as reduced lifetime, delamination of sintered electrodes, gas generation due to crack sites, and difficulty in electrolyte wetting, which affect their performance and reliability.

Innovation Solution

Surface modification of sintered electrodes with protrusions and indentations, combined with passivating compounds and impregnating agents, to enhance adhesion, reduce crack sites, and improve electrolyte wettability, using materials like silicon oxide and silanes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If sintered electrodes are used to increase volume efficiency, then volume efficiency is improved, but adhesion between sintered body and substrate deteriorates causing delamination

Engineering Contradiction:

Improvevolume efficiencyVSAvoidadhesion

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The substrate surface is modified before applying the sintered body to create protrusions and indentations that will enhance adhesion. This preliminary surface preparation ensures that when the sintered body is applied, it forms strong mechanical interlocking bonds, preventing delamination while maintaining high volume efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sintered body is designed with a porous structure containing indentations that increase surface area and provide mechanical interlocking with the substrate. This porous morphology enhances adhesion strength while maintaining the high volume efficiency characteristic of sintered electrodes.

Inventive Principle:

Principle #31Porous materials

2Volume of stationary object

If sintered electrodes are used to increase volume efficiency, then volume efficiency is improved, but crack sites are generated leading to gas generation

Engineering Contradiction:

Improvevolume efficiencyVSAvoidgas generation

Core Design Contradiction:

Volume of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The substrate surface is preliminarily modified with protrusions and indentations before applying the sintered body. This preliminary action creates a mechanically interlocking interface that reduces crack formation during subsequent processing and operation, thereby reducing gas generation from crack sites while maintaining high volume efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The surface modification structure acts as a cushioning mechanism that absorbs stress and prevents crack propagation. The protrusions and indentations create a stress-distributing interface that prevents crack site formation, thereby preventing gas generation while maintaining the high volume efficiency of sintered electrodes.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Volume of stationary object

If sintered electrodes are used to increase volume efficiency, then volume efficiency is improved, but electrolyte wettability deteriorates

Engineering Contradiction:

Improvevolume efficiencyVSAvoidelectrolyte wettability

Core Design Contradiction:

Volume of stationary objectVSEase of operation

Solution Approach 1:

The sintered body is designed with a porous structure containing indentations that increase surface area and provide capillary action for electrolyte penetration. This porous morphology enhances electrolyte wettability while maintaining the high volume efficiency characteristic of sintered electrodes.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The surface modification introduces dimensional complexity with protrusions and indentations that create capillary channels. This dimensional change enables capillary action to draw electrolyte into the sintered body, improving wettability while maintaining high volume efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Improves adhesion and reduces gas generation, enhances electrolyte wetting, and increases volume efficiency, leading to improved capacitor performance and reduced thickness of separator layers.

Implementation Method 1

it may be achieved by sintering of valve metal particles, i.e. by a heating or annealing step that merges or fuses the particles

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

a passivating compound that is configured to adsorb to crack sites of an electrode or sites of an electrode that at least partially lack an oxide layer

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 3

an impregnating compound that is configured to impregnate a portion of the surface of an electrode. Said impregnating compound is configured to increase the wettability of the surface of the electrode by the electrolyte

Methodology Applied

Scientific EffectImpregnation: Absorption (physical)

Data Source

PatentUS20260011509A1Electrode, Electrolyte, Capacitive Element, Capacitor And Processes Of Manufacturing Or Modifying Or Impregnating An Electrode

Publication Date: 2026.01.08 TDK ELECTRONICS AG

AI summary

According to the application, an electrode is provided having a substrate and a sintered body on a first main surface of said substrate. The substrate comprises a first valve metal. The sintered body comprises merged or sintered particles that comprise a second valve metal. The first main surface of the substrate is surface-modified.