Solid Electrolytic Capacitor Adhesive Layer for Enhanced Dielectric Bonding

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Solution Overview

Problem

Existing solid electrolytic capacitors face challenges in achieving optimal adherence between the dielectric and solid electrolyte layers, which affects capacitance and overall electrical performance.

Innovation Solution

Incorporating a protective adhesive layer with a polymer containing a repeating unit having a functional hydroxyl group between the dielectric and solid electrolyte layers to enhance adhesion through attraction forces such as van Der Waals, ionic bonding, and hydrogen bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a polymeric layer is included between the dielectric oxide film and the solid electrolyte layer to improve adhesion, then the adherence between layers is improved, but the device complexity increases due to additional layers and materials

Engineering Contradiction:
Improveadherence between layersVSAvoidstructure complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

A protective adhesive layer comprising a polymer with a repeating unit having a functional hydroxyl group is positioned between the dielectric layer and the solid electrolyte layer. The hydroxyl groups form hydrogen bonds and other attraction forces with both the dielectric layer and the solid electrolyte layer, serving as a chemical intermediary that enhances adhesion between these two layers.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective adhesive layer is formed from a polymer containing repeating units with functional hydroxyl groups, creating a composite material that combines the adhesive properties of the polymer with the bonding capabilities of hydroxyl groups. This composite structure provides both mechanical adhesion and chemical bonding to improve layer attachment.

Inventive Principle:
Principle #40Composite materials

2Reliability

If the adherence between dielectric and solid electrolyte layers is improved through a protective adhesive layer, then the capacitance increases, but the manufacturing process becomes more complex

Engineering Contradiction:
ImprovecapacitanceVSAvoidmanufacturing process
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The polymer in the protective adhesive layer is selected and configured with specific parameters including repeating units having functional hydroxyl groups, which can form hydrogen bonds and other attraction forces. By changing the chemical parameters of the adhesive layer, the capacitance and adherence are improved while maintaining manufacturability through controlled chemical properties.

Inventive Principle:
Principle #35Parameter changes

3Strength

If a protective adhesive layer with functional hydroxyl groups is added to enhance adhesion through attraction forces, then the adherence and capacitance are improved, but the device structure becomes more complex

Engineering Contradiction:
ImproveadherenceVSAvoidlayer structure
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The protective adhesive layer acts as a chemical intermediary between the dielectric layer and the solid electrolyte layer. The functional hydroxyl groups in the polymer form hydrogen bonds and other attraction forces with both adjacent layers, mediating the adhesion interface and improving overall adherence without requiring direct bonding between the dielectric and electrolyte layers.

Inventive Principle:
Principle #24Intermediary (Mediator)

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

This configuration improves the adherence of the layers, leading to increased capacitance and reduced equivalent series resistance (ESR), while maintaining low leakage current and stability even under high humidity and temperature conditions.

Implementation Method 1

The protective adhesive layer can, through attraction forces (e.g., van Der Waals, ionic bonding, hydrogen bonding), bond to the dielectric layer and/or the solid electrolyte layer to adhere the layers together

Methodology Applied
Scientific Effectvan Der Waals forces: Van der Waals Force

Implementation Method 2

The protective adhesive layer can, through attraction forces (e.g., van Der Waals, ionic bonding, hydrogen bonding), bond to the dielectric layer and/or the solid electrolyte layer to adhere the layers together

Methodology Applied
Scientific EffectHydrogen bonding:

Implementation Method 3

The protective adhesive layer can, through attraction forces (e.g., van Der Waals, ionic bonding, hydrogen bonding), bond to the dielectric layer and/or the solid electrolyte layer to adhere the layers together

Methodology Applied
Scientific EffectIonic bonding:

Data Source

PatentUS7460358B2Solid electrolytic capacitor containing a protective adhesive layer
Publication Date: 2008.12.02 KYOCERA AVX COMPONENTS CORP

AI summary

An electrolytic capacitor containing a protective adhesive layer positioned between the dielectric layer and the solid electrolyte layer (e.g., a conductive polymer layer, manganese dioxide) is generally disclosed. The protective adhesive layer can include a polymer having a repeating unit with a functional hydroxyl group, such as poly(vinyl alcohol). For instance, the polymer can be at least 90 mole % hydrolyzed. The polyvinyl alcohol can be a co-polymer of vinyl alcohol and a monomer, such as an acrylic ester like a methacrylic ester (e.g., methyl methacrylate).