Electrolytic Capacitor Intermediate Layer ESR Reduction
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Solution Overview
Problem
Existing electrolytic capacitors face challenges in reducing equivalent series resistance (ESR) and preventing increases in leakage current, despite the use of crosslinking agents in conductive polymer layers.
Innovation Solution
The introduction of an intermediate layer with a cation agent and anion agents, where the first anionic group has a higher electron-withdrawing property than the second anionic group, and the total number of anionic groups exceeds the number of cationic groups, enhances the formability and covering performance of the conductive polymer layers, thereby decreasing ESR and restraining leakage current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a crosslinking agent is used to heighten strength of the conductive polymer layer, then the strength and covering performance of the conductive polymer layer is improved, but the ESR cannot be sufficiently decreased and leakage current may increase
Solution Approach 1:
The patent introduces an intermediate layer between the dielectric layer and the conductive polymer layer. This intermediate layer contains a cation agent and an anion agent that modify the surface properties of the dielectric layer, enabling better adhesion and formability of the conductive polymer layer without requiring crosslinking agents, thus preventing leakage current while maintaining strength.
Solution Approach 2:
The patent changes the chemical parameters of the interface between dielectric layer and conductive polymer layer by introducing specific cationic and anionic groups. The cation agent contains a cationic group and the anion agent contains anionic groups with specific electron-withdrawing properties, creating optimal surface conditions for conductive polymer deposition without crosslinking.
2Shape
If a crosslinking agent is used to improve covering performance of the conductive polymer layer, then the covering performance is improved, but the ESR decreases insufficiently
Solution Approach 1:
The intermediate layer acts as a mediator that enhances the wetting and covering properties of the conductive polymer layer on the dielectric surface. The cationic and anionic agents in the intermediate layer create a surface that promotes uniform deposition and adhesion of the conductive polymer, achieving excellent covering performance without crosslinking.
3Device complexity
If the conductive polymer layer is formed directly on the dielectric layer, then the structure is simple, but the adhesion and formability are insufficient
Solution Approach 1:
The intermediate layer serves as a bonding intermediary between the dielectric layer and the conductive polymer layer. It provides chemical groups that interact with both layers, creating strong interfacial adhesion and improving the formability of the conductive polymer layer during deposition.
Solution Approach 2:
The intermediate layer is formed in advance before depositing the conductive polymer layer. This preliminary action prepares the surface with optimal chemical properties (cationic and anionic groups) that facilitate subsequent conductive polymer deposition, ensuring good adhesion and formability from the start.
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 decreases ESR and prevents an increase in leakage current, while also improving the voltage-resistant characteristics of the electrolytic capacitor.
Implementation Method 1
The intermediate layer includes a cation agent containing a cationic group, and an anion agent containing a first anionic group and a second anionic group
Implementation Method 2
In the intermediate layer, a total of a number of the first anionic group and a number of the second anionic group is larger than a number of the cationic group
Implementation Method 3
The first anionic group is higher in electron-withdrawing property than the second anionic group
Data Source
AI summary
An electrolytic capacitor includes: an anode body; a dielectric layer formed on the anode body; a first conductive polymer layer covering at least a part of the dielectric layer; a second conductive polymer layer covering at least a part of the first conductive polymer layer; and an intermediate layer formed between the first conductive polymer layer and second conductive polymer layer. The intermediate layer includes a cation agent containing a cationic group, and an anion agent containing a first anionic group and a second anionic group. The first anionic group is higher in electron-withdrawing property than the second anionic group. In the intermediate layer, a total of a number of the first anionic group and a number of the second anionic group is larger than a number of the cationic group.