Carbon Cathode Coating for High-Density Medical Capacitors
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Solution Overview
Problem
Existing electrochemical cells, particularly capacitors and batteries, face challenges in achieving high energy density while maintaining compact size and affordability, especially in medical devices like implantable cardioverter-defibrillators, due to bulky and expensive battery and capacitor designs.
Innovation Solution
The development of high-capacitance electrodes and methods for producing them using a specially prepared conductive fluidic suspension applied to titanium substrates within capacitors, involving a fluid dispensing apparatus with computer-controlled valves to achieve precise coating and post-processing techniques, such as annealing, to form carbon or metal oxide layers for enhanced capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery and capacitor designs are used in medical devices, then reliable energy storage is achieved, but device size and cost increase
Solution Approach 1:
The patent changes the chemical composition and physical structure parameters of the electrode materials. By using porous valve metal anodes with high surface area to volume ratio and matching cathode materials, the energy density is increased without proportionally increasing device volume. The anode structure parameters (porosity, surface area) are optimized to store more energy in a compact form.
Solution Approach 2:
The patent employs composite electrode structures combining valve metal (tantalum, niobium) with carbon-based cathode materials. This composite approach leverages the high capacitance of valve metals and the stability of carbon materials to create a high energy density capacitor that is both compact and reliable for medical device applications.
2Reliability
If conventional battery and capacitor designs are used in medical devices, then reliable energy storage is achieved, but device cost increases
Solution Approach 1:
The patent uses porous valve metal anodes that provide extremely high surface area within a small volume. This porous structure increases the effective capacitance without requiring more material, thereby reducing material costs while maintaining or improving reliability. The porous structure is formed through controlled chemical etching or electrochemical processing.
Solution Approach 2:
The patent optimizes manufacturing parameters including electrode thickness, porosity, surface area, and electrolyte composition to achieve high energy density at lower cost. By carefully controlling these parameters during fabrication, the device achieves reliable performance with reduced material usage and simplified manufacturing processes.
3Quantity of substance
If high energy density is achieved through increased electrode material, then energy capacity increases, but device volume increases
Solution Approach 1:
The patent employs porous electrode structures, particularly porous valve metal anodes, that provide extremely high surface area to volume ratios. This allows a large quantity of electroactive material to be packed into a small physical volume, dramatically increasing energy capacity without proportionally increasing device size. The porous structure enables more electrolyte contact and higher ion transport efficiency.
Solution Approach 2:
The patent implements a compact capacitor design where the cathode is positioned on the interior surface of the capacitor can, nesting the electrode structure within the minimal available space. This nested arrangement maximizes the use of available volume for energy storage materials while maintaining a compact overall device footprint suitable for implantable medical devices.
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 enables the efficient mass production of high-capacitance cathodes for capacitors, resulting in reduced size, increased energy density, and lower costs, while maintaining robust performance and manufacturability, suitable for medical and industrial applications.
Implementation Method 1
heating the substrate and the carbon-containing material to a temperature sufficient to pyrolyze the carbon-containing material and form a carbon layer on the substrate
Implementation Method 2
heating the substrate and the carbon layer in an oxygen-containing ambient for a period of time sufficient to activate the carbon layer
Data Source
AI summary
The present invention provides improved cathodes and industrialized methods for producing such cathodes using an industrial dosing valve-based electrode coating fluid emitting technique. The family of cathodes according to the present invention can be produced so that they inhabit a pre-existing metallic surface such as an inner surface of a titanium casing adjacent but insulated from direct electrical communication from an anode. Foil-type valve metal anodes as well as porous valve metal anodes formed from metallic powders may be used in conjunction with the cathodes of the present invention.