Porous Capacitor Electrodes With Conduits for Electrolyte Flow
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Solution Overview
Problem
Capacitors with increased surface area anodes, formed by fusing powder particles, face challenges in achieving both high capacitance and a desirable delivered to stored energy ratio due to tortuous and narrow pore pathways, which hinder electrolyte movement and reduce electrical porosity.
Innovation Solution
The formation of conduits within the active layer of the capacitor anode, with a medium in direct contact with the dielectric, allows for easier electrolyte flow by providing a larger pathway from the surface to deeper pores, reducing resistance and enhancing electrical porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the anode is formed by fusing powder particles to increase surface area, then capacitance is improved, but the delivered to stored energy ratio deteriorates due to tortuous and narrow pore pathways
Solution Approach 1:
The anode structure is segmented into two distinct pore systems: macro-pores (conduits) with diameters of 1-100 micrometers for efficient electrolyte transport, and micro-pores with diameters of 1-100 nanometers for high surface area capacitance. This segmentation allows each pore type to fulfill its specific function optimally, resolving the contradiction between surface area and energy delivery ratio.
Solution Approach 2:
Different regions of the anode are assigned different pore characteristics: the outer regions contain larger macro-pores for rapid electrolyte access, while the inner regions contain smaller micro-pores for high capacitance. This local differentiation of pore quality enables simultaneous optimization of both energy delivery and storage capabilities.
2Quantity of substance
If powder particles are fused together to create pores, then surface area increases, but electrolyte movement becomes hindered due to narrow and tortuous pathways
Solution Approach 1:
The pore network is segmented into a hierarchical structure where large macro-pores serve as primary transport channels for electrolyte flow, while smaller micro-pores provide surface area. This segmentation eliminates the problem of tortuous pathways by providing direct, low-resistance routes for electrolyte movement through the macro-pore conduits.
Solution Approach 2:
The invention transitions from a single-scale pore system to a multi-scale hierarchical pore system, adding a dimensional aspect to pore sizing. By incorporating pores across multiple size dimensions (macro to micro), the structure enables both efficient transport and high surface area without the compromises of a uniform pore size system.
3Ease of manufacture
If conventional porous structures are used, then manufacturing is simple, but electrical porosity remains below desired levels
Solution Approach 1:
The macro-pore conduit structure is formed preliminarily during the sintering process itself, rather than requiring subsequent complex processing steps. This preliminary formation of the transport network allows the high electrical porosity structure to be achieved as an integral part of the manufacturing process, maintaining simplicity while improving performance.
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 increases the delivered to stored energy ratio and maintains high capacitance, enabling capacitors to achieve the desired electrical porosity, particularly in applications like Implantable Cardioverter Defibrillators, by reducing resistance and improving electrolyte flow.
Implementation Method 1
The formation of the conduits causes a portion of the dielectric to convert from a first phase to a second phase
Data Source
AI summary
Fabricating a capacitor includes forming conduits in a porous layer of material. The porous layer of material has particles that each includes a dielectric on a core. The formation of the conduits causes a portion of the dielectric to convert from a first phase to a second phase. The method also includes removing at least a portion of the second phase of the dielectric from the porous layer of material.