Capacitor Element Barrier Layer and Conductive Paste
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Solution Overview
Problem
Conventional capacitor elements face challenges in enhancing overall electrical properties, particularly in reducing leakage current and equivalent series resistance, which affects their performance in electronic devices.
Innovation Solution
A method for manufacturing a capacitor element involving a metal foil with an oxide layer, a surrounding barrier layer, a base layer synthesized by chemical polymerization, and a conductive polymer layer, using a cleaning solution containing an amine and an acid to clean and dry the base layer, followed by forming a conductive paste layer with a silver paste layer, which includes a carbon paste layer for improved electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional capacitor elements are used, then manufacturing simplicity is maintained, but leakage current and equivalent series resistance cannot be sufficiently reduced
Solution Approach 1:
The capacitor element is divided into multiple functional layers: oxide layer, surrounding barrier layer, base layer, conductive polymer layer, and conductive paste layer. Each layer performs a specific function to collectively improve electrical properties while managing complexity through modular design
Solution Approach 2:
The invention uses composite material structures including the combination of oxide layer with surrounding barrier layer, base layer with conductive polymer layer, and conductive paste layer with silver paste. These composite structures enhance electrical properties by combining materials with complementary characteristics
2Reliability
If the base layer is cleaned by the cleaning solution containing amine and acid, then leakage current is reduced, but additional manufacturing steps are required
Solution Approach 1:
The cleaning step using amine and acid cleaning solution is performed at a specific stage in the manufacturing process, before forming the conductive polymer layer. This preliminary cleaning action removes contaminants that would otherwise increase leakage current, ensuring optimal electrical properties before subsequent layers are applied
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 effectively reduces leakage current to below 450 μA and equivalent series resistance to below 29 mΩ at 25 V and 10 mA after 300 hours at 125°C, enhancing the electrical properties of the capacitor element.
Implementation Method 1
preparing a cleaning solution containing an amine and an acid; cleaning the base layer by the cleaning solution
Implementation Method 2
providing a metal foil having an oxide layer formed on an outer surface of the metal foil
Implementation Method 3
a material of the base layer is synthesized by chemical polymerization
Data Source
AI summary
A capacitor element and a method of manufacturing the same are provided. The method includes steps of: providing a metal foil having an oxide layer formed on an outer surface of the metal foil; forming a surrounding barrier layer onto the oxide layer so as to divide the outer surface of the oxide layer into a first part outer surface and a second part outer surface separated from each other; forming a base layer onto the oxide layer so as to partially encapsulate the oxide layer; cleaning the base layer by a cleaning solution and then drying the base layer; forming a conductive polymer layer onto the base layer; and forming a conductive paste layer onto the conductive polymer layer.