ELECTRODE ELEMENT FOR AN ENERGY STORAGE UNIT, ENERGY STORAGE UNIT, AND METHOD FOR PRODUCING ELECTRODE ELEMENT

Abstract

An electrode element (1) for an energy storage unit (200), such as a capacitor, has an electrode body (100) made of an active electrode material (E), wherein the electrode body (100) includes one or more of: at least one cavity (110) on its surface or in its interior; at least one partial volume (120) of lower density; and/or a surface coating (D) covering at least a portion of the surface of the electrode body (100), such that the surface area covered by the surface coating (D) remains unwetted when in contact with an electrolyte. Energy storage units (200) incorporating the electrode element (1) are particularly suitable for use in implantable electrotherapeutic devices.

Claims

1. An electrode element (1) for a capacitor (200), the electrode element including an electrode body (100) made of an active electrode material (E) and a terminal lead electrically connected to the electrode body (100), wherein the electrode body (100) includes one or more of: a. a cavity (110) upon or within the electrode body (100), wherein the cavity (110) is configured to adapt electrode activity of the electrode body (100) to a predefined electrode activity; b. a partial volume (120) therein, the partial volume (120) containing electrode material (E) having a lower density than the electrode material (E) of the electrode body (100) outside of the partial volume (120), wherein the partial is volume (100) is configured to adapt the electrode activity of the electrode body (100) to a predefined electrode activity; c. a surface coating (D) thereon, wherein the surface coating (D) is configured to maintain a surface of the electrode body (100) covered by the surface coating (D) unwetted and functionally deactivated when the surface is in contact with an electrolyte.

2. The electrode element (1) of claim 1 wherein the cavity (110) or the partial volume (120) defines a separation boundary (130), the separation boundary (130) being configured to ease mechanical separation of the electrode body (100) into a first body segment (131) and a second body segment (132) at the separation boundary (130).

3. The electrode element (1) of claim 2 wherein the cavity (110) or the partial volume (120) extends along: a. an elongated path extending between edges of the electrode body (100), and b. a major portion of a distance between the edges of the electrode body (100).

4. The electrode element (1) of claim 1 wherein one or more of: a. several of the cavity (110), the cavities (110) being separate from each other, and b. several of the partial volume (120), the partial volumes (120) being separate from each other, are arrayed in spaced relationship along a path extending between edges of the electrode body (100), the path defining a separation boundary (130) configured to ease mechanical separation of the electrode body (100) into a first body segment (131) and a second body segment (132) at the separation boundary (130).

5. The electrode element (1) of claim 1 wherein: a. the electrode body (100) includes: (1) two or more partial bodies (400, 401) adjacently arrayed along a is longitudinal axis (L), (2) one or more connecting elements (410), each connecting element (410) connecting the partial bodies (400, 401) of each pair of adjacent partial bodies (400, 401), b. each partial body (400, 401) and each connecting element (410) is formed of the active electrode material (E), and c. each connecting element (410) has a smaller cross-sectional area perpendicular to the longitudinal axis (L) than its adjacent partial bodies (400, 401), whereby the cavity (110) is: (1) formed between the adjacent partial bodies (400, 401) and adjacent the connecting element (410), and (2) configured to ease mechanical separation of the adjacent partial bodies (400, 401) by severing the connecting element (410).

6. The electrode element (1) of claim 1 wherein the electrode body (100) includes: a. the cavity (110) upon or within the electrode body (100), and b. filler material (F) filling the cavity (110) of the electrode body (100), the filler material (F) having an electrode activity different from the electrode activity of the active electrode material (E).

7. The electrode element (1) of claim 6 wherein: a. the cavity (110) is within the electrode body (100), and b. the cavity (110), and the filler material (F) therein, are entirely surrounded by the active electrode material (E).

8. The electrode element (1) of claim 1 wherein the active electrode material (E) includes one or more of: a. aluminum, b. tantalum, c. niobium, and d. zirconium.

9. The electrode element (1) of claim 1 defining an electrode of a capacitor (200).

10. The electrode element (1) of claim 9 further including an implantable electrotherapeutic device having the capacitor (200) therein.

11. The electrode element (1) of claim 1 defining an anode of a capacitor (200).

12. A method for manufacturing the electrode element (1) of claim 1 including the steps of: a. forming the electrode body (100), the electrode body (100) having a first electrode activity, and b. thereafter: (1) reducing the mass of the active electrode material (E) of the electrode body (100), or (2) forming the surface coating (D) upon the electrode body (100), whereby the electrode activity of the electrode body (100) is adapted to a predefined second electrode activity different from the first electrode activity.

13. The method of claim 12 wherein the step of reducing the mass of the active electrode material (E) of the electrode body (100) includes forming the cavity (110) upon or within the electrode body (100).

14. The method of claim 12 wherein: a. the step of reducing the mass of the active electrode material (E) of the electrode body (100) includes mechanically separating the electrode body (100) into a first body segment (131) and a second body segment (132), b. the separation is along a separation boundary (130) defined on the electrode body (100), the separation boundary (130) extending along an elongated path extending between edges of the electrode body (100).

15. The method of claim 14 wherein one or more of: a. the cavity (110), and b. the partial volume (120), extends along: (1) the separation boundary (130), and (2) a major portion of the distance between the edges of the electrode body (100).

16. The method of claim 14 wherein one or more of: a. several separate cavities (110), and b. several separate partial volumes (120), are arrayed in spaced relationship along the separation boundary (130).

17. The method of claim 12 wherein: a. the electrode body (100) includes a pair of partial bodies (400, 401) adjacently arrayed along a longitudinal axis (L), b. the partial bodies (400, 401) are connected by a connecting element (410) extending therebetween, c. the connecting element (410) has a smaller cross-sectional area perpendicular to the longitudinal axis (L) than the partial bodies (400, 401), whereby the cavity (110) is formed between the partial bodies (400, 401) and adjacent the connecting element (410), a. the step of reducing the mass of the active electrode material (E) of the electrode body (100) includes mechanically separating the electrode body (100) into a first body segment (131) and a second body segment (132) by severing the connecting element (410).

18. The method of claim 12 wherein the step of reducing the mass of the active electrode material (E) of the electrode body (100) includes forming the partial volume (120) within the electrode body (100).

19. A method for manufacturing the electrode element (1) of claim 1 including the steps of: a. forming the electrode body (100), the electrode body (100) having a first electrode activity, and b. forming one or more of: (1) the cavity (110) upon or within the electrode body (100), (2) the partial volume (120) within the electrode body (100), and (3) the surface coating (D) upon the electrode body (100), such formation adapting the electrode activity of the electrode body (100) to a predefined second electrode activity different from the first electrode activity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Referring to the accompanying drawings:

[0045] FIG. 1 depicts an exemplary electrode element having cavities in the electrode body;

[0046] FIGS. 2a-2c illustrate an exemplary version of the electrode element having a cavity, and schematically depict a method for adjusting electrode activity;

[0047] FIGS. 3a-3c illustrate another exemplary version of the electrode element having a separation boundary, and schematically depict another method for adjusting electrode activity;

[0048] FIG. 4 illustrates another version of the electrode element, having partial bodies and connecting elements;

[0049] FIG. 5 illustrates another exemplary version of the electrode element having cavities formed therein;

[0050] FIG. 6 illustrates another version of the electrode element having a filler material in the interior of the electrode body;

[0051] FIG. 7 illustrates another version of the electrode element having a partial volume of different density;

[0052] FIG. 8 illustrates another version of the electrode element having a surface coating;

[0053] FIG. 9 illustrates an exemplary version of an energy storage unit.

DETAILED DESCRIPTION OF EXEMPLARY VERSIONS OF THE INVENTION

[0054] Expanding on the foregoing discussion, FIG. 1 is a sectional illustration of an exemplary electrode element 1 having a unitary electrode body 100 made of an active electrode material E. In the exemplary version depicted, the electrode body 100 has two cavities 110 or cavities, wherein one of the cavities 110 is designed as a blind hole, that is, a cavity that does not go all the way through the body 100, and the other cavity 110 is embodied as a through-hole, that is, as a cavity that goes entirely through the body 100.

[0055] The cavity 110 allows the activity of the electrode element 1 to be adjusted to a desired value as early as during manufacture of the electrode body 100, by reducing the mass of the electrode body 100. The “activity” of the electrode element 1 means the tendency to receive or release charge carriers, this tendency leading to a specific storage capacity of an energy storage unit (such as a capacitor) if the electrode element 1 is used as an electrode, in particular as an anode. This activity is in particular a function of the mass of the electrode body 100, or of the surface area of the electrode body 100 accessible to an electrolyte.

[0056] FIGS. 2a-2c depict another exemplary implementation of the electrode element 1, wherein the electrode element 1 includes an electrode body 100 and a conductively connected connecting pin 140 to which electrical connections can be made. FIG. 2a depicts a top view of the electrode element 1. The electrode body 100, which is made of the active electrode material E, has an essentially semi-circular shape, wherein a roughly semi-circular cavity 110 has been formed in the straight side of the semi-circle. FIG. 2b is a sectional view of an electrode element 1 shaped as in FIG. 2a.

[0057] FIG. 2c provides a schematic depiction of a manufacturing method for the electrode element 1. In this method, first the semi-circular electrode body 100 is made from the active electrode material E and connected to the connecting pin 140. Thereafter, an electrode piece 150 is separated from the electrode body 100, for example by cutting, sawing, or milling. In this way, the mass of the active electrode material E is reduced in a controlled manner in order to obtain an appropriate desired electrode activity when the electrode element 1 is used in an energy storage unit. In this version of the manufacturing method, no cavity 110 is made in the electrode body 100.

[0058] FIG. 3 depicts another exemplary version of the electrode element 1 in a top view (FIGS. 3a and 3b) and in section (FIG. 3c). FIG. 3a depicts the electrode element 1 prior to a separating process, and FIG. 3b depicts the electrode element 1 following the separating process. The electrode element 1 has an essentially semicircular shape and includes a unitary electrode body 100 made of an active electrode material E, and a connecting pin 140. The electrode body 100 furthermore has cavities 110 arranged along a linear path, and which may be formed as through-holes or as blind holes. Together the cavities 110 form a separation boundary or predetermined breaking point 130 that makes it possible to break or otherwise mechanically separate the electrode body 100 at the separation boundary 130 into a first body segment 131 and a second body segment 132. FIG. 3b depicts the first body segment 131 and the second body segment 132 following separation at the separation boundary 130.

[0059] FIG. 3c depicts an exemplary electrode element 1 in section, wherein the separation boundaries or predetermined breaking points 130 are defined by cavities 110 in the form of notches. After completion of the essential production steps for the electrode element 1, the mass of the electrode body 100 may be reduced by separating at the separation boundary 130 in order to adjust the activity of the electrode element 1 to a desired value, e.g., in order to calibrate the storage capacity of an energy storage unit in which the electrode element 1 is used as an electrode (in particular an anode). One of the body segments 131 and 132 may then further be used as an electrode element 1 having reduced mass and activity, here preferably the first body segment 131, which bears the connecting pin 140.

[0060] FIG. 4 depicts a sectional view of an exemplary version of the electrode element 1, which in this case has already been produced with body segments 400, 401, 402, 403 made of the active electrode material E. The body segments 400, 401, 402, 403 are connected to one another via connecting elements 410 made of the same active electrode material E (for example, a valve metal) as the body segments 400, 401, 402, 403. The body segments 400, 401, 402, 403 are connected to one another as a linear chain via the connecting elements 410, with the connecting elements 410 extending along a common longitudinal axis L. However, it is also possible to create branched structures or a two or three-dimensional arrangement of body segments of the electrode body 100.

[0061] The body segments 400, 401, 402, 403 may be broken, cut, or otherwise mechanically separated from one another at the connecting elements 410. This advantageously allows reduction of the mass of the electrode body 100 in a controlled and simple manner even after the essential production steps for the electrode element are finished, and thereby allows adjustment of the electrode activity of the electrode element 1, e.g., when used in an energy storage unit, wherein the electrode activity influences the energy storage unit's storage capacity.

[0062] The connecting elements 410 may be formed as wires or other linking structures bridging the body segments 400, 401, 402, 403. The connecting elements 410 have a smaller cross-sectional area perpendicular to the longitudinal axis L than the body segments 400, 401, 402, 403, whereby a cavity 110 is created between body segments 400, 401, 402, 403 at each connecting element 410. The connecting elements 410 thereby define separation boundaries between body segments 400, 401, 402, 403.

[0063] FIG. 5 depicts a section through an electrode body 100 of an exemplary electrode element 1 having cavities 110 defined therein. One of these cavities 110 is defined as a through-hole, while the other two cavities 110 are designed as depressions (blind holes) in the surface of the electrode body 100. Such cavities 110 may be formed during a shaping step in the production of the electrode body 100, e.g., by pressing into the electrode body 100 by means of a stamp.

[0064] By selecting the dimensions of the cavities, the mass of the active electrode material E is adjusted to a desired value in order to attain a desired activity regardless of variation in the raw electrode materials and previous production steps. This activity then assists in providing the desired storage capacity of an energy storage unit incorporating the electrode element 1.

[0065] FIG. 6 is a sectional depiction of an exemplary electrode element 1 having cavities 110 within the interior of the electrode body 100. These cavities 110 are filled with a filler material F, as depicted at reference numeral 500. This filler material F differs from the active electrode material E, and in particular does not have any active electrode properties. The filler 500 may be pressed into the electrode body 100, for example, during a shaping step for the electrode body 100. The volume of the filler 500 may be shaped, sized, and positioned as appropriate for the materials and configuration of a given electrode body 100. The filler 500 may have a particulate, liquid, or other form which accommodates the shape of the cavities 110 when poured or injected therein.

[0066] The filler material F of the filler 500 allows the mass of the active electrode material E, and thus the activity of the electrode element 1, to advantageously be adjusted to a desired value, since the active electrode material E of the cavities is replaced by the filler material F. At the same time, the mechanical stability of the electrode body 100 is increased due to use of the filler material F in the cavities 110 in place of empty voids.

[0067] FIG. 7 is a sectional depiction of another exemplary electrode element 1 wherein the surface of the electrode body 100 has a partial volume 120 therein of lower density. The electrode body 100 has the same active electrode material E both within and outside the partial volume 120, but the density of the active electrode material E within the partial volume 120 is lower than outside the partial volume 120.

[0068] The activity of the electrode element 1 is therefore reduced compared to an electrode element 1 having uniformly higher density, so that when the electrode element 1 is used as an electrode (especially as an anode) in an energy storage element, selection of the size and density of the partial volume 120 determines the element's storage capacity.

[0069] The partial volume 120 need not be disposed on the surface of the electrode body 100, but instead may be situated within the interior of the electrode body 100. Rather than being of lower density, one or more partial volumes may instead be of higher density to allow adaptation of the activity of the electrode element 1.

[0070] FIG. 8 depicts another exemplary electrode element 1 having an electrode body 100 made of the active electrode material E, and having a cover layer made of a surface coating D, for example an impregnating agent, on the surface of the electrode body 100. The surface coating D prevents wetting of the surface of the electrode body 100 with an electrolyte, thereby preventing the covered portion of the electrode body 100 from functioning as an electrode, in particular in an energy storage unit. The activity of the electrode element 1 is thereby reduced, depending on the size and configuration of the surface coating D on the electrode body 100. The surface coating D therefore allows adjustment of the storage capacity of an energy storage unit that uses the inventive electrode element 1.

[0071] As an alternative to the version of the electrode element 1 illustrated in FIG. 8, the surface coating D might cover pores or other cavities that run from the surface into the interior of the electrode body 100 (such cavities being unfilled, or alternatively having filler material therein).

[0072] FIG. 9 schematically depicts an version of an energy storage unit 200 that has anode 210 and cathode 220, wherein the energy storage unit 200 uses the electrode element 1 as an electrode, specifically as anode 210. The energy storage unit 200 is designed as an electrolytic capacitor. The electrode element 1 is made of a valve metal, such as aluminum, tantalum, niobium, or zirconium, with an oxide layer of this valve metal forming the dielectric material of the electrolytic capacitor.

[0073] The versions of the invention described above are merely exemplary, and the invention is not intended to be limited to these versions. Rather, the scope of rights to the invention is limited only by the claims set out below, and the invention encompasses all different versions that fall literally or equivalently within the scope of these claims.