Electrolytic Capacitor Electrode with Concentric Porous Layer
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Solution Overview
Problem
Conventional electrolytic capacitors face challenges in achieving high capacitance appearance ratios due to inadequate impregnation performance and increased leakage current, particularly in solid electrolytic capacitors, where the existing electrode structures do not effectively consider the capacitance appearance ratio and the impact of size reduction on dielectric properties.
Innovation Solution
The electrolytic capacitor-specific electrode member features a wire-shaped structure with a core and a concentrically arranged porous layer having alternating low and high void ratios, ensuring sufficient impregnation and reducing leakage current through a carefully designed surface area and void structure, optimized for use with solid electrolytes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the surface of the electrode member is roughened to increase surface area, then the capacitance is improved, but the impregnation performance with solid electrolyte deteriorates due to insufficient contact between dielectric and electrolyte
Solution Approach 1:
The electrode member employs a porous layer with controlled void ratios (5-50%) to enable effective impregnation with solid electrolyte while maintaining high surface area. The porous structure allows electrolyte penetration into the electrode interior, ensuring good contact between dielectric and electrolyte for reliable capacitance formation.
Solution Approach 2:
The electrode member features a layered structure with different void ratios at different depths: an outer layer with higher void ratio (5-30%) for electrolyte impregnation and an inner layer with lower void ratio (10-50%) for capacitance contribution. This spatial variation in porosity optimizes both impregnation performance and capacitance.
2Volume of moving object
If the electrode size is reduced for miniaturization, then the device dimensions are improved, but the dielectric properties and capacitance performance deteriorate
Solution Approach 1:
The invention transitions from planar electrode geometry to a three-dimensional porous structure with controlled void ratios. This dimensional transformation increases the effective surface area within a compact volume, enabling high capacitance in miniaturized electrodes through vertical pore distribution rather than horizontal expansion.
Solution Approach 2:
The electrode member incorporates a nested porous structure where pores are distributed throughout the electrode volume with varying void ratios at different depths. This nested pore configuration maximizes the dielectric-electrolyte contact area within a small volume, maintaining capacitance performance despite size reduction.
3Ease of manufacture
If a uniform porous structure is used throughout the electrode, then the manufacturing process is simplified, but the impregnation performance and capacitance distribution become nonoptimal
Solution Approach 1:
The porous layer is segmented into multiple sub-layers with different void ratios: an outer layer (5-30%) for electrolyte impregnation and an inner layer (10-50%) for capacitance contribution. This segmentation optimizes both impregnation performance and capacitance distribution while maintaining manufacturability through controlled pore formation processes.
4Reliability
If the void ratio is increased to improve electrolyte impregnation, then the impregnation performance is improved, but the structural integrity and leakage current control deteriorate
Solution Approach 1:
The electrode member employs spatially varying void ratios: higher porosity (5-30%) in the outer layer for effective electrolyte impregnation and lower porosity (10-50%) in the inner layer for structural integrity and leakage current control. This local differentiation allows simultaneous optimization of impregnation performance and electrical stability.
Solution Approach 2:
The controlled porous structure with void ratios of 5-50% provides optimal balance between electrolyte penetration and structural integrity. The porous network allows sufficient electrolyte access while maintaining mechanical strength and controlling leakage current through appropriate pore size and distribution.
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 allows for enhanced impregnation and increased capacitance appearance ratios while minimizing leakage current, effectively addressing the limitations of conventional electrode structures in achieving high performance in electrolytic capacitors.
Implementation Method 1
a porous layer which has a plurality of layers that are concentrically arranged from the core portion toward outside in a cross section of the wire-shaped base material perpendicular to an axial direction and that include two layers or more having different void ratios
Implementation Method 2
a dielectric layer formed on the wire-shaped base material
Data Source
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AI summary
An electrolytic capacitor-specific electrode member is included in an electrolytic capacitor. The electrolytic capacitor-specific electrode member has a wire shape. The electrolytic capacitor-specific electrode member includes a core portion and a porous layer (85) located around the core portion. In a cross section of the electrolytic capacitor-specific electrode member perpendicular to its axial direction, the porous layer (85) includes a plurality of layers arranged concentrically from the core portion toward outside and at least including two layers having different void ratios.