Electrolytic Capacitor Polyol Treatment for Leakage Current Suppression
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Solution Overview
Problem
The dielectric layer in existing electrolytic capacitors has many defects, leading to leakage current issues, and the film restorability methods are inadequate, especially when forming conductive solid layers with conductive polymers.
Innovation Solution
A method for manufacturing electrolytic capacitors involves forming a dielectric layer on an anode body, impregnating it with a conductive polymer solution, and then treating it with a second solution containing a polyol compound with 3 or more hydroxyl groups to enhance film restorability and reduce leakage current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric layer is formed on the anode body by surface treatment, then the capacitor structure is established, but the dielectric layer contains many defects that cause leakage current
Solution Approach 1:
The patent applies preliminary action by performing film restoration treatment with a polyol compound solution before the capacitor is put into service. This pre-treatment restores the dielectric film properties in advance, preventing leakage current issues before they occur, rather than waiting for defects to manifest during operation.
Solution Approach 2:
The patent changes the chemical parameters of the treatment solution by using a polyol compound with specific hydroxyl group content (3 or more per molecule). This parameter change in the treatment chemistry enables effective film restoration by forming a protective layer that seals defects in the dielectric, thereby suppressing leakage current.
2Productivity
If a conductive polymer layer is formed by impregnation with conductive polymer dispersion, then the capacitor achieves low ESR and high capacity, but the film restorability becomes inadequate
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: first forming the conductive polymer layer for performance, then separately applying the polyol compound treatment for film restoration. This segmentation allows each process to be optimized independently, maintaining high capacitor performance while enabling effective film restoration without interference between the two functions.
Solution Approach 2:
The polyol compound acts as an intermediary substance that mediates between the conductive polymer layer and the dielectric layer. It penetrates through the conductive polymer structure to restore the dielectric film underneath, enabling film restoration without removing or damaging the conductive polymer layer that provides the low ESR and high capacity performance.
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 method results in electrolytic capacitors with high film restorability and suppressed leakage current, achieving improved performance by effectively addressing the defects in the dielectric layer.
Implementation Method 1
the capacitor element is, after the second step, impregnated with a second treatment solution that contains a polyol compound having 3 or more hydroxyl groups per molecule
Data Source
AI summary
A method for manufacturing an electrolytic capacitor of the present disclosure includes first to third steps. In the first step, a capacitor element is prepared that includes an anode body on which a dielectric layer is formed. In the second step, the capacitor element is impregnated with a first treatment solution containing at least a conductive polymer and a first solvent. In the third step, the capacitor element is, after the second step, impregnated with a second treatment solution that contains a polyol compound having 3 or more hydroxyl groups per molecule.