Composite Capacitor Electrode for Thinner Wound Electrolytics
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Solution Overview
Problem
Conventional wound electrolytic capacitors face limitations in volume efficiency due to physical restraints in the fabrication process and functional demands, making it challenging to increase capacitance or reduce size while maintaining performance.
Innovation Solution
The development of an electrode for electrolytic capacitors, comprising a carrier substrate with a thin metallization on one or both sides, which separates the electrically functional part from the stability-providing part, allowing for thinner electrodes and increased volume efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thick unetched aluminum core is used in cathode, then sufficient stability and tensile strength are provided for roll-to-roll processes, but electrode thickness cannot be reduced and volume efficiency is limited
Solution Approach 1:
The cathode is segmented into two functional parts: a thin metallization layer (0.01-1 μm) providing electrical conductivity and a separate carrier substrate providing mechanical strength and stability. This segmentation allows each component to be optimized independently, enabling the metallization to be extremely thin while the carrier substrate ensures sufficient tensile strength for roll-to-roll processing.
Solution Approach 2:
The invention uses a composite structure combining a metallic layer (aluminum, aluminum alloy, or aluminum compound) with a carrier substrate material (polymer, paper, fabric, or composite material). This composite construction integrates the electrical properties of metal with the mechanical properties of the substrate, achieving both thin profile and structural integrity.
2Reliability
If conventional thick cathode structure is used, then sufficient electrical conductivity and capacitance are achieved, but capacitor size cannot be reduced and volume efficiency is limited
Solution Approach 1:
The cathode structure is segmented into a thin conductive metallization layer and a mechanical support carrier substrate. This allows the electrical function to be fulfilled by a minimal thickness layer (0.01-1 μm) while the carrier substrate handles mechanical requirements, enabling significant reduction in overall cathode thickness and capacitor volume.
Solution Approach 2:
The invention changes the thickness parameter of the cathode from conventional ranges (15-80 μm) to a new range (0.01-1 μm for metallization plus thin carrier substrate), achieving volume reduction while maintaining electrical performance through the optimized composite structure.
3Volume of moving object
If thin metallization is used to reduce electrode thickness, then volume efficiency increases, but sufficient tensile strength for handling in roll-to-roll processes is lost
Solution Approach 1:
The functional requirements are segmented between the metallization layer (providing electrical conductivity with minimal thickness) and the carrier substrate (providing mechanical strength). This segmentation resolves the contradiction by allowing the metallization to be extremely thin (0.01-1 μm) while the carrier substrate ensures sufficient tensile strength for roll-to-roll handling.
Solution Approach 2:
The carrier substrate acts as an intermediary that provides mechanical support to the thin metallization layer. Without this intermediary, the thin metallization would lack sufficient tensile strength; with it, the thin structure can be handled in conventional roll-to-roll processes.
Data Source
AI summary
In an embodiment an electrode for an electrolytic capacitor includes a carrier substrate and a first metallization created on a first side of the carrier substrate.