Solid Electrolytic Capacitor Pore Design for High-Voltage Capacitance
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Solution Overview
Problem
High voltage solid electrolytic capacitors face challenges in achieving high capacitance while forming thick dielectric layers and impregnating conductive polymer particles into small pores, limiting their application in high voltage environments.
Innovation Solution
A solid electrolytic capacitor design featuring a porous anode with controlled pore size distribution and a solid electrolyte containing conductive polymer particles, allowing for high volumetric wet capacitance and dielectric strength, enabling the formation of thick dielectric layers without compromising impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high capacitance powders with nano-scale particles are used to increase capacitance, then volumetric capacitance is improved, but pore size becomes too small for effective dielectric layer formation and polymer impregnation
Solution Approach 1:
The patent changes the pore size parameter from nano-scale (conventional) to micro-scale (165-270 nm), which allows both high volumetric capacitance and effective dielectric layer formation. This parameter change resolves the contradiction by finding an optimal pore size that balances capacitance density with manufacturing feasibility.
Solution Approach 2:
The patent utilizes a porous anode structure with controlled pore size distribution (165-270 nm) that maintains high surface area for capacitance while providing adequate pore dimensions for dielectric layer formation and polymer impregnation. The porous structure enables simultaneous achievement of high volumetric capacitance and manufacturability.
2Quantity of substance
If high capacitance powders with nano-scale particles are used to increase capacitance, then volumetric capacitance is improved, but impregnation of conductive polymer particles becomes difficult
Solution Approach 1:
The patent changes the pore size parameter from nano-scale to micro-scale (165-270 nm), which provides sufficient space for conductive polymer particle impregnation while maintaining high volumetric capacitance. This parameter adjustment resolves the contradiction between capacitance density and impregnation effectiveness.
3Strength
If thick dielectric layers are formed for high voltage applications, then voltage tolerance is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent changes the pore size parameter to an optimal range (165-270 nm) that enables uniform thick dielectric layer formation (70 nm or more) with consistent quality. This parameter optimization resolves the contradiction by making thick dielectric layer manufacturing feasible through controlled pore architecture.
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 capacitor achieves high volumetric wet capacitance of 3,900 μF/cm³ or more and dielectric strength of 0.6 V/nm or more, supporting high voltage applications with improved performance.
Implementation Method 1
The porous anode is formed from a sintered valve metal powder that is anodically oxidized to form a dielectric layer thereon
Implementation Method 2
impregnating a dispersion of conductive polymer particles into the porous anode
Data Source
AI summary
A solid electrolytic capacitor containing a porous anode and a solid electrolyte is provided. The porous anode is formed from a sintered valve metal powder that is anodically oxidized to form a dielectric layer thereon having a dielectric thickness of about 70 nm or more, wherein the porous anode has a pore size distribution in which the pores have a size of from about 165 to about 270 nm at a pore volume corresponding to at least 80% of the total pore volume and exhibits a volumetric wet capacitance of about 3,900 μF/cm3 or more. The solid electrolyte contains conductive polymer particles that are disposed within the pores of the porous anode. Further, the solid electrolytic capacitor exhibits a dielectric strength of about 0.6 V/nm or more.