Sintered Capacitor Electrode Surface Structure for Delamination Control

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Solution Overview

Problem

Capacitors with high volume efficiency face issues such as reduced lifetime, delamination of sintered electrodes, gas generation due to crack sites, and difficulty in electrolyte wetting, which affect their performance and reliability.

Innovation Solution

Surface modification of the substrate with protrusions and indentations, combined with passivating compounds and impregnating agents, enhances adhesion and wettability, reducing delamination and gas generation, and improving electrolyte interaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If sintered electrodes are used to increase volume efficiency, then volume efficiency is improved, but delamination occurs and lifetime is reduced

Engineering Contradiction:

Improvevolume efficiencyVSAvoidlifetime

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The substrate surface is modified before applying the sintered electrode material. Protrusions and indentations are created on the substrate surface in advance to provide mechanical interlocking features that prevent delamination during subsequent processing and operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The substrate surface is given non-uniform local properties through surface modification. Different regions have protrusions and indentations that create localized adhesion zones, enhancing the bond between the substrate and sintered electrode at critical interfaces while maintaining overall structural integrity.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If sintered electrodes are used to increase volume efficiency, then volume efficiency is improved, but gas generation increases due to crack sites

Engineering Contradiction:

Improvevolume efficiencyVSAvoidgas generation

Core Design Contradiction:

Volume of moving objectVSObject-generated harmful factors

Solution Approach 1:

Passivating compounds are applied in advance to seal potential crack sites and defect regions on the sintered electrode surface before the electrode is assembled into the capacitor. This preliminary passivation prevents electrolyte penetration and subsequent gas-generating reactions at vulnerable locations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The passivation process converts potentially harmful crack sites and defect regions into sealed, inert zones. The same features that could generate gas through electrolyte contact are instead transformed into stable, passivated regions that enhance overall electrode reliability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Volume of moving object

If sintered electrodes are used to increase volume efficiency, then volume efficiency is improved, but electrolyte wettability decreases

Engineering Contradiction:

Improvevolume efficiencyVSAvoidelectrolyte wettability

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

Impregnating agents are applied selectively to specific regions of the sintered electrode, particularly to areas with higher surface area such as protrusions and indentations. This localized impregnation enhances wettability at critical interfaces where electrolyte contact is most important for electrical performance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The surface properties of the sintered electrode are modified by introducing impregnating agents that change the surface energy and wettability parameters. This allows the electrode to maintain its compact sintered structure while achieving improved electrolyte penetration and contact.

Inventive Principle:

Principle #35Parameter changes

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

The proposed solution increases volume efficiency, reduces delamination and gas formation, and enhances electrolyte wetting, leading to improved capacitor performance and reliability.

Implementation Method 1

a compound which is configured to adsorb to crack sites or at least sites of the electrode which at least partially lack an oxide layer

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

an impregnating compound which is configured to impregnate a portion of a surface of the electrode and which is configured to increase the wettability of the surface of the electrode by the electrolyte

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS20260011510A1Electrode, electrolyte, capacitive element, capacitor and processes of manufacturing or modifying or impregnating an electrode

Publication Date: 2026.01.08 TDK ELECTRONICS AG

AI summary

According to the application, an electrode is provided having a substrate and a sintered body on a first main surface of said substrate. The substrate comprises a first valve metal. The sintered body comprises merged or sintered particles that comprise a second valve metal. The first main surface of the substrate is surface-modified