Solid Electrolytic Capacitor Anomalous Charging Mitigation
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Solution Overview
Problem
Conventional solid electrolytic capacitors using in situ polymerized polymers exhibit high leakage current and fail at high voltages, and those using PEDOT:PSS dispersions show anomalous charging characteristics, especially at high temperatures or in dry conditions.
Innovation Solution
A solid electrolytic capacitor design featuring a sintered porous anode body, a dielectric formed by anodically oxidizing the anode in an electrolyte containing an ionic compound and oxidizing agent, and a conductive polymer solid electrolyte, which maintains stable electrical properties even at extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If in situ polymerized polymers are used as solid electrolyte, then low ESR and non-burning failure mode are achieved, but high leakage current and failure at high voltages occur
Solution Approach 1:
The patent changes the chemical composition parameters of the solid electrolyte by using PEDOT:PSS dispersion with specific ratios (PEDOT:PSS ratio of 1:0.8 to 1:1.2) and adding secondary polymers, which reduces leakage current while maintaining low ESR and safe failure mode
Solution Approach 2:
The patent creates a composite solid electrolyte structure by combining PEDOT:PSS with secondary polymers (such as polyacrylic acid, polyacrylamide, or polyvinyl alcohol) in specific weight ratios, achieving synergistic effects that reduce leakage current while maintaining electrical conductivity and safe failure characteristics
2Object-generated harmful factors
If PEDOT:PSS dispersions are used as solid electrolyte, then leakage current is improved, but anomalous charging characteristic occurs at high temperatures or dry conditions
Solution Approach 1:
The patent combines PEDOT:PSS with secondary polymers having different thermal and hygroscopic properties, creating a composite structure that maintains stable charging characteristics across temperature and humidity variations while preserving low leakage current performance
Solution Approach 2:
The patent optimizes the local composition within the solid electrolyte layer by controlling the distribution and ratio of PEDOT:PSS to secondary polymer, ensuring that specific regions provide thermal stability while others maintain electrical conductivity under varying environmental conditions
3Ease of manufacture
If conventional solid electrolyte materials are used, then manufacturing is simplified, but electrical properties become unstable at extreme conditions
Solution Approach 1:
The patent modifies the formulation parameters of the solid electrolyte by incorporating secondary polymers in controlled amounts (1-50 wt% of total polymer content) and adjusting PEDOT:PSS concentration, achieving stable electrical properties at extreme temperatures and humidity while maintaining compatibility with existing manufacturing processes
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 capacitor does not exhibit anomalous charging current and maintains low leakage current and stable electrical properties at high temperatures and in dry conditions, with improved capacitance and resistance values.
Implementation Method 1
a dielectric that overlies the anode body... formed by anodically oxidizing the anode in an electrolyte containing an ionic compound and oxidizing agent
Data Source
AI summary
A solid electrolytic capacitor containing a capacitor element is provided. The capacitor element contains a sintered porous anode body, a dielectric that overlies the anode body, and a solid electrolyte that overlies the dielectric that includes a conductive polymer. The capacitor does not exhibit an anomalous charging current when charged at a constant voltage rate increase of 120 volts per second, as determined at an operating frequency of 120 Hz and temperature of about 23° C.