Laser-Drilled Anode Foils for Uniform Electrolytic Capacitor Tunnels
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Solution Overview
Problem
The challenge in manufacturing electrolytic capacitors for implantable devices like ICDs is the non-uniform distribution of tunnels in anode foils due to electrochemical etching, leading to reduced surface area and increased resistance, which affects energy density and overall capacitor performance.
Innovation Solution
Using laser ablation to form tunnels in anode foils, allowing for precise control over tunnel arrangement and diameter, thereby improving packing density and reducing equivalent series resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrochemical etching is used to create tunnels in anode foils, then the number of tunnels can be increased to raise capacitance, but the tunnel distribution becomes non-uniform causing reduced surface area and increased resistance
Solution Approach 1:
The patent replaces the electrochemical etching process with a mechanical drilling process. A drill bit is used to physically create tunnels through the anode foil in a controlled manner, ensuring uniform distribution and spacing of tunnels while maintaining high capacitance through increased tunnel quantity.
Solution Approach 2:
The patent changes the fundamental parameter of tunnel creation from chemical etching to mechanical drilling. This parameter change allows for precise control over tunnel depth, diameter, and spacing, achieving uniform distribution throughout the anode foil structure.
2Quantity of substance
If tunnel density is increased to maximize capacitance, then energy density improves, but tunnel merging occurs reducing effective surface area
Solution Approach 1:
By substituting mechanical drilling for electrochemical etching, the process achieves precise control over tunnel spacing and depth. The mechanical drill bit creates cleanly defined tunnels that maintain their individuality even at high densities, preventing merging and preserving effective surface area for capacitance.
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
Laser ablation enables higher capacitance and energy density in capacitors by ensuring uniform tunnel distribution, enhancing the performance of electrolytic capacitors used in implantable devices.
Implementation Method 1
A laser is used to drill or punch a plurality of tunnels through the anode foil
Data Source
AI summary
A capacitor and methods of processing an anode metal foil are presented. The capacitor includes a housing, one or more anodes disposed within the housing, one or more cathodes disposed within the housing, one or more separators disposed between an adjacent anode and cathode, and an electrolyte disposed around the one or more anodes, one or more cathodes, and one or more separators within the housing. The one or more anodes each include a metal foil that includes a first plurality of tunnels through a thickness of the metal foil in a first ordered arrangement having a first diameter, and a second plurality of tunnels through the thickness of the metal foil having a second ordered arrangement and a second diameter greater than the first diameter.