Electrolytic Capacitor Dielectric Layer Polymer Incorporation
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Solution Overview
Problem
Existing electrolytic capacitors face issues with leak current due to insufficient film quality and denseness of the dielectric layer, particularly when using low molecular compounds like phosphoric acid in chemical conversion treatments.
Innovation Solution
Incorporating an organic polymer with acidic functional groups into the dielectric layer, which enhances adhesiveness and density, and using a combination of treatment liquids to control the thickness and distribution of the dielectric layer, thereby reducing leak current and improving electrostatic capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chemical conversion treatment is performed using low molecular compounds like phosphoric acid, then the dielectric layer can be formed, but the film quality and denseness are insufficient, resulting in high leak current
Solution Approach 1:
The patent uses a composite treatment liquid containing both a low molecular compound (phosphoric acid) and a polymer compound (polyacrylic acid). The low molecular compound provides initial dielectric layer formation, while the polymer compound penetrates and fills the film, enhancing denseness and reducing leak current. This composite approach combines the advantages of both material types to achieve high film quality and low leak current simultaneously.
Solution Approach 2:
The patent changes the chemical composition parameters of the treatment liquid by incorporating polymer compounds with specific molecular weights and functional groups. This parameter modification allows the treatment liquid to achieve both good film formation and high denseness, resolving the contradiction between film quality and leak current reduction.
2Quantity of substance
If the dielectric layer is made thinner to increase electrostatic capacitance, then the capacitance increases, but the voltage resistance decreases
Solution Approach 1:
The composite treatment liquid with polymer compounds creates a denser dielectric layer structure that maintains high voltage resistance even when the layer is thin. The polymer fills voids and creates a more uniform film, allowing thin dielectric layers to achieve both high capacitance and adequate voltage resistance.
Solution Approach 2:
The patent utilizes the porous structure of the anode body and fills it with polymer material during treatment. This creates a dielectric layer with optimized porosity - maintaining the surface area needed for high capacitance while the polymer filling ensures sufficient density for voltage 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
The approach effectively suppresses leak current and enhances the denseness and thickness of the dielectric layer, leading to improved voltage resistance and electrostatic capacitance in electrolytic capacitors.
Implementation Method 1
a dielectric layer formed by anodization
Implementation Method 2
The chemical conversion treatment of the related art is performed by dipping the anode body into a chemical conversion liquid
Data Source
AI summary
An electrolytic capacitor includes an anode body, a dielectric layer disposed on the anode body, and a cathode body. An organic polymer attached to the dielectric layer is disposed between the dielectric layer and the cathode body. The organic polymer has one or more groups selected from an acidic group and residues of the acidic group, and at least one of the one or more groups is incorporated into the dielectric layer.