Electrolytic Capacitor Production Using Aprotic Solvent Impregnation
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Solution Overview
Problem
Conventional electrolytic capacitors have poor withstand voltage characteristics due to low restoration ability of the dielectric layer, limiting their impregnation property and overall performance.
Innovation Solution
A method for producing electrolytic capacitors involving a series of impregnation steps using treatment solutions with specific solvents, including aprotic solvents, to enhance the impregnation property of the electrolyte solution into the capacitor element, improving the restoration ability and permeability of the dielectric layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a solid electrolyte layer is used as cathode material, then the capacitor achieves small size and low ESR, but the restoration ability of the dielectric layer deteriorates
Solution Approach 1:
The patent combines solid electrolyte layer and electrolyte solution in a composite structure. The solid electrolyte layer provides low ESR and small size, while the electrolyte solution penetrates into the dielectric layer to restore its breakdown strength and self-healing ability, achieving synergistic effects of both materials
Solution Approach 2:
The electrolyte solution is applied to specifically penetrate and restore the dielectric layer's local properties where damage occurs, while the solid electrolyte layer maintains its function as the primary cathode material for low ESR and compact structure
2Reliability
If an electrolyte solution is impregnated into the capacitor element, then the restoration ability of the dielectric layer improves, but the device complexity increases
Solution Approach 1:
The electrolyte solution is impregnated into the capacitor element during the manufacturing process before final assembly and sealing. This preliminary action ensures the dielectric layer is restored early, preventing subsequent damage and simplifying the overall manufacturing流程
Solution Approach 2:
The patent merges the electrolyte solution impregnation step with the existing manufacturing process flow, combining multiple functions (dielectric restoration, electrolyte distribution, and sealing) into an integrated process rather than separate sequential steps
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 method significantly improves the impregnation property and self-restoration ability of the dielectric layer, reducing leakage current and enhancing electrostatic capacity while maintaining low equivalent series resistance (ESR).
Implementation Method 1
a second step of impregnating the capacitor element with a first treatment solution containing a first solvent and a conductive polymer; a third step of impregnating, after the second step, the capacitor element with a second treatment solution containing a second solvent; and a fourth step of impregnating, after the third step, the capacitor element with an electrolyte solution containing a third solvent
Implementation Method 2
Both the second solvent and the third solvent are an aprotic solvent
Data Source
AI summary
A method for producing an electrolytic capacitor includes: a first step of preparing a capacitor element that includes an anode body on which a dielectric layer is formed; a second step of impregnating the capacitor element with a first treatment solution containing a first solvent and a conductive polymer; a third step of impregnating, after the second step, the capacitor element with a second treatment solution containing a second solvent; and a fourth step of impregnating, after the third step, the capacitor element with an electrolyte solution containing a third solvent. Both the second solvent and the third solvent are an aprotic solvent.