Monofunctional Amine Primer for Capacitor Polymer Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for producing solid electrolytic capacitors face challenges in achieving uniform surface coverage with polymeric outer layers, leading to high residual current and insufficient thermal stability, particularly at edges and corners, due to inhomogeneous layer formation and mechanical stress during encapsulation.
Innovation Solution
A process involving a primer solution with a monofunctional amine and carboxylic acid is applied to the capacitor body, followed by a conjugated polymer solution, to enhance the coverage and stability of the polymeric outer layer, ensuring better edge and corner coverage and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If in situ polymerization is used to form the polymeric outer layer, then the layer can be formed directly on the capacitor body, but the layer becomes inhomogeneous and edges/corners are insufficiently covered
Solution Approach 1:
A primer layer is applied to the capacitor body surface before applying the polymeric outer layer. This preliminary action prepares the surface to ensure uniform coverage and proper adhesion, particularly at edges and corners, resolving the inhomogeneity issue while maintaining the direct formation advantage.
Solution Approach 2:
The primer layer acts as an intermediary between the capacitor body and the polymeric outer layer. This intermediate layer improves adhesion and ensures uniform distribution of the outer layer, particularly addressing the edge coverage problem while preserving the simplicity of direct formation.
2Reliability
If the polymeric outer layer is used as a mechanical buffer, then residual current is reduced, but thermal stability at high temperatures remains insufficient
Solution Approach 1:
A composite structure is created with a primer layer and a polymeric outer layer. The primer layer provides thermal stability and adhesion, while the polymeric outer layer provides mechanical buffering and reduces residual current. This composite approach resolves both requirements simultaneously.
Solution Approach 2:
Different layers are assigned different functional properties: the primer layer is optimized for thermal stability and adhesion, while the polymeric outer layer is optimized for mechanical buffering. This local differentiation of material properties resolves the contradiction between residual current reduction and thermal stability.
3Manufacturing precision
If multiple coating cycles are used to achieve uniform coverage, then edge coverage improves, but the production process becomes more complex and prone to faults
Solution Approach 1:
The primer layer is applied as a preliminary step before the polymeric outer layer, creating a prepared surface that ensures uniform coverage in a single或少量 coating cycles. This eliminates the need for multiple repetitive coating cycles while maintaining excellent edge coverage.
Solution Approach 2:
The primer layer serves as an intermediary that facilitates uniform application of the polymeric outer layer, reducing the number of coating cycles needed. This intermediate step simplifies the overall production process while ensuring precise edge coverage.
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 process results in solid electrolytic capacitors with low residual current, low equivalent series resistance, and high thermal stability, improving their performance and reliability in electronic circuits.
Implementation Method 1
a primer solution e) which comprises at least one monofunctional amine and at least one carboxylic acid is applied to the capacitor body
Implementation Method 2
a solution or dispersion a) which comprises a conjugated polymer b) and a solvent or dispersant d) is then applied and the solvent or dispersant d) is then at least partially removed
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a process for producing an electrolytic capacitor, the process comprising process steps i) ii): i) providing a capacitor body (1) that comprises - an electrode body (2) of an electrode material, - a dielectric (3) which at least partially covers the surface of this electrode material, and - a solid electrolyte (4) at least comprising an electrically conductive material which at least partially covers the dielectric surface; ii) applying a primer solution e) to the capacitor body (1), followed by an application of a solution or dispersion a) comprising a conjugated polymer b) and a solvent or dispersant d), followed by an at least partial removal of the solvent or dispersant d) for the formation of the polymeric outer layer (5) that is formed onto the capacitor body (1); wherein the primer solution e) comprises at least one monofunctional amine and at least one carboxylic acid.