Sintered Electrode Connection Post for Implantable Capacitors
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Solution Overview
Problem
The challenge in energy storage devices is the fragility of thin or brittle anodes and cathodes, which makes interconnection difficult, leading to potential malfunctions and reduced performance due to increased equivalent series resistance.
Innovation Solution
The use of sintered electrodes with a sintered portion on one side of a substrate and a connection post through the substrate, allowing for secure interconnection without breaking, and filled with electrolyte to increase surface area and capacitance, enhancing energy density and reducing ESR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thin or brittle current collectors are used to reduce weight and increase energy density, then energy density is improved, but the fragility increases making interconnection difficult and causing potential malfunctions
Solution Approach 1:
The electrode substrate is designed with differentiated local properties: a sintered portion with high surface area and capacitance for energy storage, and a connection portion that is substantially free of sintering for mechanical strength and reliable electrical connection. This local quality differentiation allows the electrode to simultaneously achieve high energy density in the active region and high reliability in the connection region.
2Volume of moving object
If thin or brittle current collectors are used to reduce device size, then device size is reduced, but manufacturing complexity increases due to difficulty in handling and interconnecting
Solution Approach 1:
The electrode structure incorporates a connection portion that is substantially free of sintering, providing a robust, non-brittle region that is easy to handle and interconnect during manufacturing. This allows standard high-volume manufacturing processes to be used without special precautions for fragile materials, while the sintered portion maintains the required high surface area for energy storage.
3Device complexity
If conventional interconnection methods are used for thin current collectors, then device complexity is maintained, but equivalent series resistance increases reducing performance
Solution Approach 1:
The connection post merges multiple functions into a single component: it provides mechanical support for stacking electrodes, establishes electrical connection between electrodes and terminals, and creates a low-resistance current path. This integrated approach reduces equivalent series resistance compared to separate interconnection elements while maintaining manageable device complexity.
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 results in improved energy density, reduced risk of breakage during handling, and increased manufacturing efficiency, enabling the creation of smaller, high-energy capacitors suitable for implantable medical devices with enhanced performance.
Implementation Method 1
the first electrode comprising a substrate with a sintered portion on a side of the substrate
Implementation Method 2
filled with electrolyte to increase surface area and capacitance
Data Source
AI summary
An example includes a capacitor case sealed to retain electrolyte, at least one anode disposed in the capacitor case, the at least one anode comprising a sintered portion disposed on a substrate, an anode conductor coupled to the substrate in electrical communication with the sintered portion, the anode conductor sealingly extending through the capacitor case to an anode terminal disposed on the exterior of the capacitor case with the anode terminal in electrical communication with the sintered portion, a second electrode disposed in the capacitor case, a separator disposed between the second electrode and the anode and a second electrode terminal disposed on an exterior of the capacitor case and in electrical communication with the second electrode, with the anode terminal and the second electrode terminal electrically isolated from one another.