Solid Electrolytic Capacitor Ion Trapping Resin Adhesion
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Solution Overview
Problem
Existing solid electrolytic capacitors face characteristic deterioration due to metal ion migration and suffer from inadequate adhesive strength and flowability issues between different resin layers in their construction.
Innovation Solution
Incorporating an ion trapping member made of a first resin with dispersed ion trapping agents and an external insulation member made of a second resin with high affinity for the first resin, which covers the lead out portion and connects to the anode terminal, effectively suppressing metal ion migration and enhancing adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mask layer is made of a second resin different from the first resin forming the external insulation member, then metal ion migration is suppressed, but flowability of the first resin deteriorates and adhesive strength between resin layers is insufficient
Solution Approach 1:
The invention uses the same resin material for both the mask layer and the external insulation member, ensuring homogeneous material composition throughout. This eliminates the interface between different resin types, preventing flowability deterioration and ensuring sufficient adhesive strength while maintaining metal ion migration suppression functionality.
2Ease of manufacture
If the external insulation member is formed with a resin having low affinity for the mask layer resin, then manufacturing is simplified, but adhesive strength between layers is insufficient
Solution Approach 1:
By using the same resin material for the mask layer and external insulation member, the invention ensures high affinity between layers due to material homogeneity. This naturally provides sufficient adhesive strength without complicating the manufacturing process, as the same resin can be applied in sequence with compatible processing conditions.
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 prevents metal ion migration, maintains capacitor performance, and ensures strong adhesive strength between resin layers, reducing the risk of short circuits and capacitance loss, as demonstrated by high temperature and humidity tests.
Implementation Method 1
The ion trapping member comprises a first resin and an ion trapping agent dispersed in the first resin. Accordingly, migration of metal ions can be suppressed
Implementation Method 2
the external insulation member is made of the second resin having the high affinity for the first resin. Accordingly, deterioration of flowability of the second resin can be suppressed upon forming the external insulation member, achieving sufficient adhesive strength between the first resin and the second resin
Data Source
AI summary
In a capacitor element of a solid electrolytic capacitor, a solid electrolytic layer has an edge portion near a root of a lead-out portion. An anode terminal is connected to the lead out portion at a position away from the root of the lead out portion. An ion trapping member includes a first resin and an ion trapping agent dispersed in the first resin. The ion trapping member covers the whole periphery of at least a part of the lead out portion directly or via the dielectric layer between the edge portion of the solid electrolytic layer and the anode terminal. An external insulation member includes a second resin having a high affinity for the first resin. The external insulation member envelops the capacitor element and covers at least a part of the ion trapping member, a part of the anode terminal and a part of a cathode terminal.