# US 12,191,089 B2 · Performance of porous capacitor electrodes

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- Number: US 12,191,089 B2
- Document ID: US12191089B2
- Status: Granted
- Kind: B2
- Application number: 18/395,384
- Filed: 2023-12-22
- Published: 2024-04-18
- Granted: 2025-01-07
- Earliest claimed: 2017-10-09
- Assignees: Pacesetter, Inc.
- Applicants: Pacesetter, Inc.
- Inventors: Ralph Jason Hemphill; David R. Bowen; Thomas F. Strange; Xiaofei Jiang
- Web page: https://patentgrep.com/patent/US12191089B2

## CPC

- H01G 9/0029: {Processes of manufacture}
- H01G 9/0032: {formation of the dielectric layer}
- H01G 9/045: based on aluminium
- H01G 9/048: characterised by their structure (H01G11/22 takes precedence)
- H01G 9/055: Etched foil electrodes
- H01G 9/07: Dielectric layers
- H01G 9/145: Liquid electrolytic capacitors (H01G11/00 takes precedence)
- H01G 11/84: Processes for the manufacture of hybrid or EDL capacitors, or components thereof
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)

## 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.

## Claims

### 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;
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.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

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

### Claim 6 (depends on 1)

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.

### Claim 7 (depends on 1)

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.

### Claim 8 (depends on 1)

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

### Claim 9 (depends on 8)

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.

### Claim 10 (depends on 1)

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.

### Claim 11 (depends on 10)

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

### Claim 12 (depends on 11)

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.

### Claim 13 (depends on 1)

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

### Claim 14 (depends on 1)

The capacitor of claim 1, 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.

### Claim 15 (depends on 1)

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.

### Claim 16 (depends on 1)

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.

### Claim 17 (depends on 16)

The capacitor of claim 16, 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.

### Claim 18 (depends on 16)

The capacitor of claim 16, 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.