Electrolytic Capacitor ESR Reduction via Polymer Coagulation
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Solution Overview
Problem
Existing methods for producing electrolytic capacitors face challenges in reducing equivalent series resistance (ESR) due to limitations in forming conductive solid layers with conductive polymers.
Innovation Solution
A method involving a three-step process: preparing a capacitor element with a dielectric layer, impregnating it with a conductive polymer solution, and then coagulating the polymer using a coagulant solution, where a significant portion of the initial solvent remains to facilitate uniform attachment and reduce ESR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive polymer layer is formed by impregnating with a conductive polymer dispersion, then a conductive solid layer is created, but the ESR cannot be sufficiently reduced due to formation conditions limitations
Solution Approach 1:
The patent changes the physical-chemical parameters of the conductive polymer layer formation process by introducing a coagulant that alters the solvent state. The coagulant causes the solvent to precipitate the conductive polymer, transforming it from a dissolved state to a coagulated solid state, thereby improving ESR characteristics while maintaining manufacturing feasibility
Solution Approach 2:
The patent introduces a coagulant as an intermediary substance that mediates between the conductive polymer solution and the final conductive solid layer. The coagulant facilitates the phase transition of the conductive polymer from dissolved to coagulated state, enabling better ESR performance without complicating the manufacturing process
2Reliability
If the conductive polymer is coagulated using a coagulant, then ESR is reduced, but the process complexity increases with multiple treatment steps
Solution Approach 1:
The patent merges the coagulation step with the existing impregnation process by applying the coagulant in the form of a spray or solution during or after the impregnation step. This integration allows the coagulation function to be added without significantly increasing process complexity, as the coagulant application can be combined with existing treatment line operations
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 effectively reduces ESR while maintaining high electrostatic capacity, as demonstrated by the production of capacitors with low ESR values and large electrostatic capacities.
Implementation Method 1
a third step of impregnating, after the second step, the capacitor element, in which at least a part of the first solvent remains, with a second treatment solution containing a coagulant to coagulate the conductive polymer
Data Source
AI summary
A method for producing an electrolytic capacitor according to the present disclosure includes a first step of preparing a capacitor element that includes an anode body having a dielectric layer; a second step of impregnating the capacitor element with a first treatment solution containing at least a conductive polymer and a first solvent; and a third step of impregnating, after the second step, the capacitor element, in which at least a part of the first solvent remains, with a second treatment solution containing a coagulant to coagulate the conductive polymer.