Electrolytic Capacitor Manufacturing via Conductive Solid Dispersion
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Solution Overview
Problem
Conventional wound solid electrolytic capacitors face issues with low solder heat resistance, increased leak current, and dielectric layer damage due to the use of electrically conductive solid polymers, which lead to uneven formation of the electrically conductive solid layer and complications in the production process.
Innovation Solution
A method involving the impregnation of a capacitor element with a dispersion solution containing particles of an electrically conductive solid and a solvent to form a planar electrically conductive solid layer on the electrode foils and separator, followed by an electrolytic solution, eliminating the need for oxidative polymerization and subsequent washing and drying processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If oxidative polymerization is used to form the electrically conductive solid layer, then the layer can be formed in place, but the dielectric layer is damaged and the formation becomes uneven
Solution Approach 1:
The electrically conductive solid layer is formed preliminarily on the electrode foils before assembling the capacitor element. This preliminary formation ensures uniformity and prevents dielectric layer damage during subsequent assembly and use, while still achieving in-place functionality in the final product.
Solution Approach 2:
A preliminary formed electrically conductive solid layer acts as an intermediary between the electrode foil and the electrolyte solution. This intermediate layer provides a uniform conductive surface that prevents direct contact between the electrolyte and the dielectric layer, thereby preventing damage and ensuring even current distribution.
2Ease of manufacture
If oxidative polymerization is used to form the electrically conductive solid layer, then the layer can be formed internally, but additional washing and drying processes are required
Solution Approach 1:
The harmful oxidative polymerization step is extracted and removed from the manufacturing process. Instead, a preliminary formation process is used that does not require subsequent washing and drying, thereby simplifying the overall manufacturing process while still achieving the desired internal electrically conductive solid layer.
Solution Approach 2:
The patent uses a disposable preliminary formed layer approach where the electrically conductive solid layer is formed in a simple process without requiring complex washing and drying equipment. This eliminates the need for additional process steps and reduces manufacturing complexity.
3Use of energy by moving object
If electrically conductive solid polymer is used as electrolyte, then higher electric conductivity is achieved, but solder heat resistance deteriorates and leak current increases
Solution Approach 1:
The patent uses a composite structure consisting of an electrically conductive solid layer formed preliminarily on the electrode foil and an electrolyte solution filling the remaining space. This composite approach combines the high conductivity benefit of solid polymers with the reliability and heat resistance of liquid electrolytes, achieving both high conductivity and good solder heat resistance.
Solution Approach 2:
The electrically conductive solid layer is applied locally on the electrode foil surfaces where high conductivity is most needed for current collection and distribution. The bulk of the electrolyte remains in liquid form to provide thermal management and reliability, creating a local quality differentiation that optimizes both conductivity and heat resistance.
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 results in a capacitor with improved solder heat resistance, reduced leak current, and enhanced long-term performance by ensuring a uniform and protective electrically conductive solid layer, which can effectively repair damaged areas and simplify the production process.
Implementation Method 1
impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive solid or aggregates thereof and a solvent to form a planar electrically conductive solid layer
Implementation Method 2
impregnating the capacitor element having the electrically conductive solid layer with an electrolytic solution
Data Source
AI summary
A method for manufacturing an electrolytic capacitor comprising the steps of: forming a capacitor element having a pair of electrode foils wound with a separator interposed therebetween; impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive solid or aggregates thereof and a solvent to form a planar electrically conductive solid layer having the particles of the electrically conductive solid or the aggregates thereof on the surfaces of the electrode foils and the separator; and impregnating the capacitor element having the electrically conductive solid layer with an electrolytic solution.