Electrolytic Capacitor Impregnation via Conductive Polymer and Electrolyte Solution
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Solution Overview
Problem
The restoration ability of electrolytic capacitors is limited due to poor impregnation of electrolyte solutions into the dielectric layer, which affects their withstand voltage characteristics and electrostatic capacity.
Innovation Solution
A method involving a capacitor element with an anode body and cathode body, impregnated with a conductive polymer solution followed by an electrolyte solution, ensuring the electrolyte solution permeates the dielectric layer, enhancing its restoration ability and electrostatic capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a solid electrolyte layer is used as cathode material, then the capacitor achieves small size and large capacity, but the restoration ability of the dielectric layer is poor and withstand voltage characteristics are low
Solution Approach 1:
The patent combines a solid electrolyte layer (conductive polymer) with an electrolyte solution to create a hybrid cathode structure. The solid electrolyte layer provides high capacity and compact size, while the electrolyte solution penetrates the dielectric layer to restore it and improve withstand voltage characteristics. This merging of solid and liquid electrolyte components resolves the contradiction between capacity and reliability.
Solution Approach 2:
The cathode is constructed as a composite material system comprising both solid conductive polymer electrolyte and liquid electrolyte solution. The solid electrolyte provides electrical conductivity and capacitance, while the liquid electrolyte components (such as carboxylic acids or their salts) penetrate and restore the dielectric layer, creating a composite structure that achieves both high capacity and high withstand voltage characteristics.
2Stability of the object's composition
If the electrolyte solution impregnation is insufficient, then the capacitor structure remains compact, but the restoration ability of the dielectric layer is poor
Solution Approach 1:
The patent applies preliminary action by first forming the solid electrolyte layer on the dielectric layer before introducing the electrolyte solution. This sequence ensures that the dielectric layer is already in place and can be effectively restored when the electrolyte solution penetrates it. The preliminary formation of the solid electrolyte layer facilitates subsequent electrolyte solution impregnation and dielectric restoration.
Solution Approach 2:
The solid electrolyte layer acts as an intermediary that facilitates the penetration and distribution of the electrolyte solution into the dielectric layer. The conductive polymer structure provides a pathway and medium through which the electrolyte solution components can effectively reach and restore the dielectric layer, simplifying the overall impregnation process while ensuring thorough restoration.
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 method improves the impregnation property of the electrolyte solution, resulting in enhanced electrostatic capacity and reduced equivalent series resistance (ESR) in electrolytic capacitors.
Implementation Method 1
the electrolyte solution permeates a surface and an inside of the dielectric layer
Implementation Method 2
a solid electrolyte layer including a conductive polymer as a cathode material, which is provided on the anode foil
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 a conductive polymer and a first solvent; and a third step of impregnating the capacitor element with an electrolyte solution after the second step, the capacitor element being, in the third step, impregnated with the electrolyte solution while including a liquid.