The performance of porous capacitor electrodes

Patent metadata

Field	Value
Publication number	US-2024128024-A1
Application number	US-202318395384-A
Country	US
Kind code	A1
Filing date	Dec 22, 2023
Priority date	Oct 9, 2017
Publication date	Apr 18, 2024
Grant date	—

Abstract

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.

First claim

1 . A capacitor, comprising:
an anode that includes an active layer having both pores and conduits,
the conduits extending from a surface of the active layer into the active layer by more than 65% of a thickness of the active layer and less than 100% of the thickness of the active layer, and
an average width of the conduits is 2 or more times an average width of the pores; and
an electrolyte in the pores and the conduits, the pores being open to the conduits such that the electrolyte can flow between the pores and the conduits.

2 . The capacitor of claim 1 , wherein an average width of the pores is less than 10 μm.

3 . The capacitor of claim 1 , wherein each of the conduits has a length that is substantially straight in cross section.

4 . The capacitor of claim 1 , wherein the pores terminate at the conduits and are open to the conduits.

5 . The capacitor of claim 1 , wherein an average width of the conduits is less than 50 times an average width of the pores.

6 . The capacitor of claim 1 , wherein the anode includes a current collector having a flat surface,
the conduits each includes a terminal end, the active layer contacts the flat surface of the current collector such that a portion of the active layer is located between the terminal ends of the conduits and the flat surface of the conduit.

7 . The capacitor of claim 1 , wherein the current collector is selected from the group consisting of a thin layer, foil, a mesh, and a screen.

8 . The capacitor of claim 1 , wherein the conduits are arranged in a periodic two-dimensional pattern.

9 . The capacitor of claim 8 , wherein the periodic two-dimensional pattern is selected from a group consisting of a hexagonal pattern, a square pattern, and a triangular pattern.

10 . The capacitor of claim 1 , wherein the active layer includes particles having a dielectric on a core and the pores being located between the particles.

11 . The capacitor of claim 10 , wherein the electrolyte is in direct physical contact with the dielectric on different particles.

12 . The capacitor of claim 11 , wherein a portion of the electrolyte located in the conduits is in direct physical contact with the dielectric on different particles.

13 . The capacitor of claim 1 , wherein the active layer includes sintered particles and the pores provide a tortuous pathway between the particles.

14 . The capacitor of claim 1 , wherein the conduits each has a length that is substantially straight in cross section.

15 . The capacitor of claim 1 , wherein the active layer includes particles that each has a dielectric on a core and the pores are located between the particles, and
a portion of the particles each defines a portion of an interior of one of the conduits and each has the dielectric on the core of the particle such that the core of the particle is exposed to an interior of the conduit.

16 . The capacitor of claim 15 , wherein each of the particles that define the portion of the interior of one of the conduits has the dielectric on the core such that the dielectric is not present between the core and the interior of the conduit defined by the core.

17 . The capacitor of claim 1 , wherein a ratio of (1) a surface area of the active layer surface that is not occupied by an opening to one of the conduits to (2) a surface area of the active layer that is occupied by the opening to one of the conduits is greater than 20:1 and less than 500:1.

18 . The capacitor of claim 1 , wherein the active layer includes particles that each has a dielectric on a core such that the pores are located between the particles, the dielectric including corundum oxide.

19 . The capacitor of claim 18 , wherein each of the conduits has an interior and the dielectric on a portion of the particles defines at least a portion of the interiors of the conduits,
the dielectric on the particles that defines the interiors having the corundum oxide in at least a portion of the dielectric that defines at least one the interiors.

20 . The capacitor of claim 18 , wherein the dielectric on the particles that defines at least a portion of at least one of the interiors does not include corundum oxide in a portion of the dielectric that defines at least one of the interiors.

Assignees

• Pacesetter Inc

Inventors

• Hemphill Ralph Jason
• Bowen David R
• Strange Thomas F
• Jiang Xiaofei

Classifications

• H01G9/0029 Primary

  Processes of manufacture · CPC title

• H01G9/0032

  formation of the dielectric layer · CPC title

• H01G9/045

  based on aluminium · CPC title

• H01G9/048 Primary

  characterised by their structure (H01G11/22 takes precedence) · CPC title

• H01G9/055

  Etched foil electrodes · CPC title