Solid Electrolytic Capacitor Carbon Layer Fixation
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Solution Overview
Problem
Conventional solid electrolytic capacitors face issues with the fragility of carbon layers, leading to cracks and deterioration in capacitor characteristics due to the lack of adequate fixation and contact between the carbon layer and the silver paste layer.
Innovation Solution
A method involving the use of an aqueous polymer to coat and fix the carbon layer, followed by the formation of a silver paste layer, where the binder resin in the silver paste is bound with the aqueous polymer, enhancing the strength and contact between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a carbon layer is formed on the dielectric layer, then the capacitor structure is completed, but the carbon layer becomes fragile and cracks occur
Solution Approach 1:
The patent creates a composite structure by forming a carbon layer containing both conductive polymer and carbon particles. This composite material combines the advantages of both materials: the conductive polymer provides adhesion and flexibility, while carbon particles provide electrical conductivity. The resulting carbon layer is less fragile and more resistant to cracking compared to using carbon particles alone.
Solution Approach 2:
The patent changes the composition parameters of the carbon layer by incorporating conductive polymer in addition to carbon particles. This parameter change transforms the carbon layer from a fragile particulate structure to a more robust composite structure with improved mechanical strength and reduced crack formation.
2Ease of manufacture
If the carbon layer is formed directly on the dielectric layer, then the fabrication process is simplified, but adequate fixation and contact with the silver paste layer is not achieved
Solution Approach 1:
The carbon layer is formulated as a composite containing both conductive polymer and carbon particles. The conductive polymer component acts as a binder that provides adequate fixation to the dielectric layer and creates good contact with the silver paste layer, while maintaining fabrication simplicity through a single layer formation step.
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 approach improves the reliability and performance of solid electrolytic capacitors by reducing the occurrence of cracks and enhancing characteristics such as equivalent series inductance (ESL) capacitance and leakage current.
Implementation Method 1
by the step of bringing an aqueous polymer into contact with the carbon layer, the carbon layer formed on the solid electrolytic layer can be coated with the aqueous polymer. The carbon layer is thus fixed by the aqueous polymer.
Implementation Method 2
by carrying out the step of forming the silver paste layer, the binder resin constituting the silver paste layer and the aqueous polymer are bound together, so that the aqueous polymer and the silver paste layer come into close contact.
Data Source
AI summary
A method of fabricating a solid electrolytic capacitor of an aspect includes the steps of preparing an anode element with a dielectric layer formed on a surface thereof, forming a solid electrolytic layer on the dielectric layer, forming a carbon layer on the solid electrolytic layer, bringing an aqueous polymer into contact with the carbon layer, and forming a silver paste layer on the aqueous polymer. A method of fabricating a solid electrolytic capacitor and a solid electrolytic capacitor that can be improved in characteristics can thus be obtained.