Electrolytic Capacitor Dual Polymer Layer Hydroxy Compound ESR Reduction
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Solution Overview
Problem
Conventional electrolytic capacitors with solid electrolyte layers face issues of high equivalent series resistance (ESR) and leakage current due to random addition of additives, which deteriorate the film quality and do not effectively reduce ESR.
Innovation Solution
The use of a solid electrolyte layer with a first and second conductive polymer layer, where the second conductive polymer layer includes a polymer dopant and a hydroxy compound with two or more alcoholic or phenolic hydroxy groups and a melting point between 40°C to 150°C, to improve conductivity and reduce ESR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional additives are randomly added to the solid electrolyte layer, then the attempt is made to improve conductivity, but the film quality deteriorates and leakage current increases
Solution Approach 1:
The patent changes the chemical parameters of the solid electrolyte layer by incorporating a hydroxy compound with specific molecular structure (two or more hydroxy groups) and controlled content (1-100 parts by mass relative to conductive polymer). This parameter change improves conductivity while suppressing leakage current, resolving the contradiction between improving conductivity and reducing harmful leakage current.
Solution Approach 2:
The patent creates a composite solid electrolyte layer by combining conductive polymer with hydroxy compound in specific proportions. This composite material approach achieves both improved conductivity and reduced leakage current, whereas random addition of conventional additives fails to achieve both goals simultaneously.
2Reliability
If additives are added to reduce ESR, then the attempt is made to improve electrical performance, but the film quality deteriorates
Solution Approach 1:
The patent optimizes the chemical composition parameters of the solid electrolyte layer by incorporating hydroxy compound at controlled concentrations (1-100 parts by mass relative to conductive polymer). This parameter optimization reduces ESR while maintaining excellent film quality, resolving the contradiction between improving electrical performance and maintaining manufacturing precision.
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 effectively suppresses leakage current and reduces ESR, enhancing the film quality and conductivity of the electrolytic capacitor while maintaining a stable solid state at room temperature.
Implementation Method 1
The second conductive polymer layer includes a polymer dopant and a hydroxy compound
Implementation Method 2
the hydroxy compound has a melting point ranging from 40° C. to 150° C., inclusive
Data Source
AI summary
An electrolytic capacitor includes an anode body, a first conductive polymer layer, and a second conductive polymer layer. The anode body includes a dielectric layer. The first conductive polymer layer covers at least a part of the dielectric layer. The second conductive polymer layer covers at least a part of the first conductive polymer layer. The first conductive polymer layer includes a first conductive polymer. The second conductive polymer layer includes a second conductive polymer. At least one of the first conductive polymer layer and the second conductive polymer layer further includes a hydroxy compound. The hydroxy compound has two or more alcoholic hydroxy groups or two or more phenolic hydroxy groups, and has a melting point ranging from 40° C. to 150° C., inclusive.