Electrolytic Capacitor Carbon Silver Cathode Layer
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Solution Overview
Problem
Conventional cathode lead-out layers in electrolytic capacitors are not dense enough to effectively prevent air from contacting the solid electrolyte layer, leading to deterioration of the conductive polymer and increased equivalent series resistance (ESR).
Innovation Solution
A cathode lead-out layer comprising a conductive carbon layer with silver, which is formed by applying a carbon paste containing carbon particles and silver particles, enhances the gas barrier property and reduces air permeation, thereby protecting the solid electrolyte layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional carbon layer is used in the cathode lead-out layer, then the structure is simple and manufacturing is easy, but the layer is not dense enough to effectively prevent air from contacting the solid electrolyte layer
Solution Approach 1:
The patent applies composite materials by combining carbon particles with silver particles in the carbon layer. This composite structure creates a denser, more effective barrier against air permeation while maintaining electrical conductivity. The silver particles fill gaps between carbon particles, enhancing the protective function without significantly increasing structural complexity.
Solution Approach 2:
The patent changes the compositional parameters of the carbon layer by incorporating silver particles with specific size ranges (0.01-10 μm) alongside carbon particles. This parameter modification transforms the carbon layer from a simple carbon-based structure to a composite material with optimized density and barrier properties, effectively preventing air contact with the solid electrolyte layer.
2Reliability
If the carbon layer is made denser to prevent air permeation, then protection of the solid electrolyte layer is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The use of composite materials comprising carbon particles and silver particles achieves enhanced gas barrier properties through the natural packing and filling effects of the two particle types. The silver particles fill interstices between carbon particles, creating a denser structure without requiring complex manufacturing processes. The carbon paste formulation and application method remain relatively simple, maintaining ease of manufacture.
3Reliability
If silver particles are added to the carbon layer to enhance gas barrier property, then air permeation is reduced, but the composition and manufacturing process become more complex
Solution Approach 1:
The patent incorporates silver particles into the carbon paste composition to create a composite material that provides superior gas barrier properties. The silver particles, combined with carbon particles, form a dense network that effectively prevents air permeation and protects the conductive polymer in the solid electrolyte layer. The composition includes carbon particles (1-10 μm), silver particles (0.01-10 μm), and binder resin, forming a practical composite formulation.
Solution Approach 2:
The patent modifies the compositional parameters of the carbon paste by specifying particle size ranges for carbon (1-10 μm) and silver (0.01-10 μm) particles, along with binder resin content (1-20 parts by weight per 100 parts of carbon and silver). These parameter optimizations achieve effective gas barrier properties while maintaining manufacturability through controlled particle size distributions and binder ratios.
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 effectively suppresses the deterioration of the conductive polymer and reduces the equivalent series resistance (ESR) of the electrolytic capacitor, even under high temperature and humidity conditions.
Implementation Method 1
the carbon layer contains carbon particles and silver... enhances the gas barrier property and reduces air permeation
Data Source
AI summary
An electrolytic capacitor includes a capacitor element. The capacitor element includes an anode body, a dielectric layer that covers at least a part of the anode body, a solid electrolyte layer that covers at least a part of the dielectric layer, and a cathode lead-out layer that covers at least a part of the solid electrolyte layer. The cathode lead-out layer includes a carbon layer and a silver-paste layer. The carbon layer is conductive and covers at least a part of the solid electrolyte layer. And the silver-paste layer covers at least a part of the carbon layer. The carbon layer contains carbon particles and silver.