Hybrid Capacitor Anode Tunnels for High DSR Capacitance
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Solution Overview
Problem
Existing aluminum electrolytic capacitors face challenges in achieving high delivered to stored energy ratios (DSR) due to limitations in anode design, such as the need for multiple layers and reduced electrolyte movement, which affects capacitance and efficiency, especially in applications like implantable cardioverter-defibrillators requiring DSR of at least 90%.
Innovation Solution
The development of a capacitor anode with active layers on a current collector featuring tunnels that extend from one face to the other, allowing for increased electrolyte movement and thinner active layers, which enhances capacitance without sacrificing DSR, by using fused particles and a current collector with optimized porosity and tunnel density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple anode layers are used to generate desired capacitance, then the surface area increases, but the production process complexity increases
Solution Approach 1:
The patent creates three-dimensional tunnels extending through the anode layer from one surface to the other, transforming the traditional two-dimensional surface area approach into a three-dimensional volume utilization approach. This allows electrolyte penetration deep into the anode structure, effectively increasing the active surface area without stacking multiple layers, thereby simplifying the production process while maintaining high capacitance
2Quantity of substance
If traditional anode design is used, then capacitance is achieved, but the delivered to stored energy ratio (DSR) decreases
Solution Approach 1:
The patent employs a porous anode structure with interconnected tunnels that allow rapid electrolyte transport throughout the anode volume. This porous architecture ensures that nearly all stored energy can be quickly delivered to the external circuit, achieving DSR values of 90% or higher while maintaining high capacitance through increased effective surface area
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 design allows for a thicker anode without compromising DSR, achieving capacitance increases similar to smaller particle sizes while maintaining high energy efficiency, with the anode thickness exceeding 500 μm without a sharp DSR drop, thus meeting the requirements of high-energy applications like implantable cardioverter-defibrillators.
Implementation Method 1
The current collector includes tunnels that extend from a first face of the current collector to a second face of the current collector
Data Source
AI summary
A capacitor has an anode with one or more active layers that each includes fused particles positioned on a current collector. The current collector includes tunnels that extend from a first face of the current collector to a second face of the current collector.