Electrolytic Capacitor Heat Barrier Layer Thermal Management

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Solution Overview

Problem

Electrolytic capacitors degrade due to thermal conduction and internal pressure increases when exposed to high temperatures, leading to electrical characteristic degradation and sealing issues, especially when containing conductive polymers.

Innovation Solution

Incorporating a heat barrier layer with metallic oxides or metal hydroxides on the outer packaging member, which provides electrical insulation and suppresses thermal conduction, or using a porous particle-based outer packaging resin layer that acts as a heat barrier, preventing short circuits and maintaining sealing integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the electrolytic capacitor is exposed to high temperature environment, then the thermal conduction to the capacitor element increases, but the electrical characteristic of the capacitor element degrades

Engineering Contradiction:

Improvethermal conductionVSAvoidelectrical characteristic

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

An infrared reflecting layer is introduced as an intermediary between the outer packaging member and the capacitor element. This layer reflects infrared radiation and reduces thermal conduction to the capacitor element, thereby protecting it from high temperature damage while maintaining the capacitor's overall thermal management

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The infrared reflecting layer is applied selectively to the outer packaging member, creating a localized thermal barrier only where needed - on the surface exposed to high temperature environments - while leaving the internal structure and other components unchanged

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If the capacitor element contains conductive polymer as solid electrolyte, then the gas generation increases due to thermal decomposition, but the internal pressure increases and sealing property degrades

Engineering Contradiction:

Improveconductive polymerVSAvoidsealing property

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The infrared reflecting layer serves as a thermal barrier that mediates between the external high temperature environment and the conductive polymer inside the capacitor element, reducing the thermal decomposition of the polymer and thereby preventing gas generation and internal pressure increase

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The infrared reflecting layer provides beforehand protection by reflecting thermal radiation before it reaches the capacitor element, cushioning the element against thermal stress and preventing the thermal decomposition that would lead to gas generation and sealing degradation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Temperature

If an infrared reflecting layer is provided on the outer packaging member, then the thermal conduction to the capacitor element is reduced, but the electrical insulation property may be compromised

Engineering Contradiction:

Improvethermal conductionVSAvoidelectrical insulation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The infrared reflecting layer is constructed using composite materials that combine infrared reflection capability with electrical insulation properties, allowing the layer to simultaneously reduce thermal conduction while maintaining electrical insulation between the outer packaging member and the capacitor element

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The infrared reflecting layer is applied only to the outer packaging member surface, creating a localized thermal barrier that does not interfere with the electrical insulation properties of the main capacitor element structure and internal components

Inventive Principle:

Principle #3Local quality

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 solution effectively suppresses thermal conduction and internal pressure increases, enhancing the reliability and sealing properties of electrolytic capacitors even at high temperatures, preventing electrical characteristic degradation and short circuits.

Implementation Method 1

an infrared reflecting layer is provided on a surface of the film. Consequently, the degradation of the electrochemical element due to thermal conduction to the electrochemical element in the electrochemical device is prevented

Methodology Applied

Scientific EffectInfrared reflection: Infrared Radiation

Implementation Method 2

The heat barrier layer has an electrical insulation property, and contains at least one of metallic oxide and metal hydroxide

Methodology Applied

Scientific EffectThermal conduction suppression: Thermal Insulation

Implementation Method 3

The outer packaging resin layer includes a porous particle having an electrical insulation property

Methodology Applied

Scientific EffectThermal insulation through porous structure: Porosity

Data Source

PatentUS11049663B2Electrolytic capacitor

Publication Date: 2021.06.29 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

An electrolytic capacitor includes a capacitor element, a lead member electrically connected to the capacitor element, an outer packaging member in which the capacitor element and a part of the lead member are sealed, and a heat barrier layer that covers at least a part of the outer packaging member. The heat barrier layer has an electrical insulation property, and contains at least one of metallic oxide and metal hydroxide.