Solid Electrolytic Capacitor with Nanometer-Enhanced Polymer

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Solution Overview

Problem

Existing solid electrolytic capacitor structures face limitations in achieving enhanced electrical performances, particularly in terms of capacitance, equivalent series resistance, dissipation factor, and leakage current, due to the lack of integration of nanometer materials in their design.

Innovation Solution

The integration of a conductive polymer composite material layer, comprising a conductive polymer material mixed with first and second nanometer materials, where the nanometer materials include fully embedded and partially exposed structures, enhances the electrical performances by improving electronic properties, thermal stabilization, and polymer impregnation ratio.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional solid electrolytic capacitor structure is used, then manufacturing simplicity is maintained, but electrical performances (capacitance, ESR, dissipation factor, leakage current) are limited

Engineering Contradiction:

Improveelectrical performancesVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by integrating nanometer materials (such as metal nanoparticles, metal nanowires, carbon nanotubes, or graphene) into the conductive polymer composite material layer. This composite structure enhances electrical performances including capacitance, equivalent series resistance, dissipation factor, and leakage current while maintaining the overall capacitor structure

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating partially exposed nanometer structures that are strategically positioned to contact either the oxide layer or the carbon paste layer. This localized enhancement at specific interfaces optimizes electrical performance without requiring complete restructuring of the entire capacitor

Inventive Principle:

Principle #3Local quality

2Reliability

If nanometer materials are integrated into the conductive polymer layer, then electrical performances increase, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical performancesVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by controlling the embedding depth of nanometer structures (fully embedded vs. partially exposed) and their distribution within the conductive polymer composite material layer. These parameter adjustments optimize electrical performance while managing manufacturing complexity through controlled variation rather than complete structural redesign

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If fully embedded and partially exposed nanometer structures are used, then polymer impregnation ratio and thermal stabilization improve, but structural complexity increases

Engineering Contradiction:

Improvethermal stabilizationVSAvoidnanometer structure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent applies porous materials by incorporating nanometer structures with high surface area-to-volume ratios (such as carbon nanotubes, graphene, or metal nanowires) into the conductive polymer layer. These porous/nanometer structures enhance polymer impregnation ratio and thermal stabilization while the partial exposure configuration manages the complexity by limiting the structures to specific regions

Inventive Principle:

Principle #31Porous materials

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 use of nanometer materials in the conductive polymer composite layer significantly increases the electrical performances of solid electrolytic capacitors, including capacitance, equivalent series resistance, dissipation factor, and leakage current, outperforming prior art without nanometer materials.

Implementation Method 1

The conductive polymer composite material layer includes a conductive polymer material and a first nanometer material mixed with the conductive polymer material... significantly increases the electrical performances of solid electrolytic capacitors, including capacitance, equivalent series resistance, dissipation factor, and leakage current

Methodology Applied

Scientific EffectConduction (electrical): Conduction (electrical)

Implementation Method 2

each first capacitor includes a valve metal foil, an oxide insulation layer for enclosing the valve metal foil

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Data Source

PatentUS10068711B2Solid electrolytic capacitor package structure for increasing electrical performances and method of manufacturing the same, and capacitor unit thereof

Publication Date: 2018.09.04 APAQ TECH

AI summary

The present disclosure provides a solid electrolytic capacitor package structure for increasing electrical performances and a method of manufacturing the same, and a capacitor unit thereof. The capacitor unit includes at least one first capacitor, the at least one first capacitor includes a conductive polymer composite material layer. The conductive polymer composite material layer includes a conductive polymer material and a first nanometer material mixed with the conductive polymer material, and the first nanometer material includes a plurality of first fully embedded nanometer structures completely enclosed by the conductive polymer material and a plurality of first partially exposed nanometer structures partially exposed from the conductive polymer material.