Solid Electrolytic Capacitor Semiconductor Layer Formation
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Solution Overview
Problem
Existing methods for producing solid electrolytic capacitors with high capacitance and low ESR (equivalent series resistance) face challenges in efficiently forming a semiconductor layer within a short time, leading to prolonged production times and reduced yield due to the formation of excess polymer during electrolytic polymerization.
Innovation Solution
The method involves temporarily applying a reverse voltage during electrolytic polymerization using an electric conductor as an anode and a negative electrode plate as a cathode, allowing for the formation of a semiconductor layer on an oxide dielectric film layer, which shortens production time and improves yield by optimizing the polymerization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrolytic polymerization is conducted using direct current with an electric conductor as anode and negative electrode plate as cathode, then a semiconductor layer is formed on the oxide dielectric film layer, but a large amount of polymer is also formed on the cathode which may lead to short circuit and prolonged production time
Solution Approach 1:
The patent applies periodic action by switching between direct current mode (for forming semiconductor layer on anode) and reverse voltage mode (for removing polymer from cathode) in alternating cycles during electrolytic polymerization. This periodic switching prevents excessive polymer accumulation on the cathode while maintaining efficient semiconductor layer formation, thereby reducing total production time and preventing short circuits.
Solution Approach 2:
The patent employs inversion by temporarily reversing the polarity of the electrodes during the electrolytic polymerization process. By applying reverse voltage where the original polarity is inverted, the method effectively removes excess polymer from the cathode surface, preventing short circuits and enabling shorter processing times while maintaining semiconductor layer quality.
2Productivity
If the time for forming a semiconductor layer is shortened, then production efficiency is improved, but the capacity of the solid electrolytic capacitor may be insufficient
Solution Approach 1:
The periodic switching between direct current and reverse voltage modes optimizes the polymerization process by preventing cathode polymer accumulation that would otherwise require longer processing times. This allows for shorter total formation times while maintaining sufficient semiconductor layer quality and capacitor capacity, thereby improving production efficiency without sacrificing reliability.
Solution Approach 2:
The method maintains continuous useful action by ensuring that both electrodes remain productive throughout the process - the anode continuously forms semiconductor layer while the reverse voltage periodically cleans the cathode. This continuous optimization of both electrodes' performance enables shorter processing times while maintaining adequate capacitor capacity.
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 approach enables the production of solid electrolytic capacitors with sufficient capacity and low ESR, significantly reducing the time required to form the semiconductor layer and enhancing overall production efficiency, allowing for multiple cycles within a day.
Implementation Method 1
a semiconductor layer is formed by electrolytic polymerization on an electric conductor having an oxide dielectric film layer
Data Source
AI summary
The present invention relates to a production method of a solid electrolytic capacitor element wherein a semiconductor layer is formed by electrolytic polymerization on an oxide dielectric film formed on the surface of an electric conductor and an electrode layer is laminated thereon, comprising passing current providing a period for temporarily applying a reverse voltage during the electrolytic polymerization passing current using an electric conductor having a dielectric layer formed thereon as an anode and a negative electrode plate placed in the electrolyte as a cathode; a solid electrolytic capacitor element produced by the method; a solid electrolytic capacitor obtained from the solid electrolytic capacitor element and use thereof. According to the present invention, a solid electrolytic capacitor element in which a high quality semiconductor layer is formed in a short time can be produced, which enables to produce a solid electrolytic capacitor having a good ESR property.