3D Printed Valve Metal Anodes for Capacitors
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Solution Overview
Problem
Conventional methods for producing capacitors with valve metal anodes face challenges such as oxygen absorption during production, which impairs electrical properties, and insufficient bonding between the anode and connecting wire, leading to mechanical failure, while methods like 3D printing with metal pastes require additional steps for binder removal and solvent decomposition, affecting energy density.
Innovation Solution
A 3D printing method using valve metal powders without solvents or binders, where layers of valve metal powder are consolidated via selective laser irradiation to form a composite, allowing for integrated electrical connections and controlled density, porosity, and structure, enhancing mechanical stability and energy storage density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pressing and sintering methods are used to produce valve metal anodes, then the anodes can be manufactured with standard processes, but the minimum thickness is significantly limited by the diameter of the connecting wire and oxygen absorption impairs electrical properties
Solution Approach 1:
The patent changes the manufacturing process parameters from conventional pressing and sintering to 3D printing with selective laser melting. This enables precise control of anode thickness independent of wire diameter while maintaining low oxygen content through controlled atmosphere processing, thereby improving both manufacturing precision and electrical properties
Solution Approach 2:
The 3D printing process allows different regions of the anode to have different densities and structures optimized for their specific functions. The connecting wire integration area can be locally optimized for bonding strength while other regions are optimized for electrical performance and energy storage, resolving the conflict between thickness control and electrical properties
2Reliability
If reducing conditions are applied to lower oxygen content in anodes, then electrical properties improve, but the bonding strength between connecting wire and anode deteriorates
Solution Approach 1:
The connecting wire is integrated into the anode structure during the 3D printing process itself, before the anode is removed from the build platform. The wire is embedded in the powder bed and bonded simultaneously with the anode formation through selective laser melting, ensuring strong bonding without subsequent wire attachment that would be compromised by reducing conditions
Solution Approach 2:
The patent merges the anode fabrication process with the wire bonding process into a single 3D printing operation. The wire and anode are created as an integrated structure in one process step, eliminating the need for separate bonding operations that would be affected by oxygen content and reducing conditions
3Length of moving object
If 3D printing with metal pastes containing solvents and binders is used, then thin anodes can be produced, but additional steps for binder removal and solvent decomposition are required, affecting energy density
Solution Approach 1:
The patent extracts and eliminates the harmful components (solvents and binders) from the printing material system. Instead of using metal pastes containing these additives, the invention uses pure valve metal powders that can be directly sintered without requiring binder removal or solvent decomposition steps, thereby simplifying the process and maintaining high energy density
Solution Approach 2:
The patent replaces complex paste formulations requiring multiple processing steps with simple metal powders that can be directly consolidated. The simplified material system (pure metal powder) acts as a disposable, single-step solution that eliminates the need for subsequent binder removal and solvent decomposition operations
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 method enables the production of thin anodes with improved electrical and mechanical properties, higher energy storage density, and increased wire pull strength, overcoming the limitations of conventional methods by eliminating the need for solvents and binders and integrating connections within the component.
Implementation Method 1
consolidating at least a portion of the valve metal powder of the first layer by selective irradiation with a laser
Implementation Method 2
consolidating at least a portion of the valve metal powder of the first layer by selective irradiation with a laser
Implementation Method 3
consolidating at least a portion of the valve metal powder of the first layer by selective irradiation with a laser
Data Source
AI summary
A method for producing an electrical component via a 3D printing includes preparing a first layer which includes a valve metal powder, consolidating at least a portion of the valve metal powder of the first layer via a first selective irradiation with a laser, applying a second layer which includes the valve metal powder to the first layer, consolidating at least a portion of the valve metal powder of the second layer via a second selective irradiation with the laser so as to form a composite of the first layer and of the second layer, applying respective additional layers which include the valve metal powder to the composite, and consolidating at least a portion of the valve metal powder of the respective additional layers via a respective additional selective irradiation with the laser to thereby obtain the electrical component.