Solid Electrolytic Capacitor Corner Structure for Lower Leakage
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Solution Overview
Problem
The reliability of electrolytic capacitors with solid electrolytes is compromised due to defects in the dielectric layer at the corner portions of the anode body, leading to increased leakage current and mechanical weakness.
Innovation Solution
The anode body is modified to have a curved surface or chamfered corner portions, reducing defects in the dielectric layer and enhancing mechanical strength, with a compact surface texture to ensure uniform solid electrolyte layer thickness and improved stress resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anode body has sharp corner portions, then the manufacturing process is simple, but the dielectric layer develops defects and mechanical strength decreases
Solution Approach 1:
The corner portions of the anode body are rounded or chamfered before the dielectric layer is formed. This preliminary structural modification prevents defects in the dielectric layer during subsequent formation processes, eliminating the need for complex defect repair steps while improving reliability.
Solution Approach 2:
Only the corner portions of the anode body are modified with different surface characteristics (rounded or chamfered) compared to the main body. This localized structural change addresses the specific problem of corner defects without altering the overall simple manufacturing process or adding complexity to the entire device.
2Manufacturing precision
If the corner portions are modified to reduce defects, then the dielectric layer quality improves, but the manufacturing process becomes more complex
Solution Approach 1:
The anode body corners are prepared with rounded or chamfered shapes before dielectric layer formation. This preliminary action ensures that the dielectric layer forms uniformly without defects at the corners, achieving high manufacturing precision through a simple preparatory step rather than complex control processes.
3Quantity of substance
If the solid electrolyte layer is made thin for high capacitance, then the capacitance increases, but the mechanical strength and reliability decrease
Solution Approach 1:
The anode body corner portions are given different surface characteristics (rounded or chamfered) compared to the main body. This local structural quality ensures uniform dielectric layer formation at corners, preventing defects that would otherwise require thicker electrolyte layers for compensation, thus maintaining high capacitance with adequate mechanical strength.
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 reduces leakage current, enhances mechanical strength, and improves the capacitor's reliability by minimizing defects and thermal stress concentration, while maintaining a uniform solid electrolyte layer thickness.
Implementation Method 1
the step of preparing the anode body includes a step of irradiating a laser beam to at least part of the corner portion
Implementation Method 2
a dielectric layer is formed on the surface of the anode body
Implementation Method 3
a solid electrolyte layer covering at least part of the dielectric layer
Data Source
AI summary
An electrolytic capacitor including a capacitor element that includes an anode body being porous, a dielectric layer formed on the surface of the anode body, and a solid electrolyte layer covering at least part of the dielectric layer. The anode body has a plurality of principal surfaces and a corner portion. The corner portion includes a plurality of side portions connecting between the principal surfaces, and one or more vertex portions connecting between the principal surfaces. A surface layer X of at least part of the corner portion is more compact in texture than a surface layer Y of the principal surface adjacent to the surface layer X.