Solid Electrolytic Capacitor Separator Layout for Lower ESR
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrolytic capacitors face issues with high electrical resistance due to the distance from the electrode foil to the extraction part, leading to increased ESR, and the formation of metal bundles can damage the dielectric surface and complicate insulation maintenance.
Innovation Solution
The electrolytic capacitor design includes a configuration where first and second separators project from the anode foil, facing each other with a conductive polymer forming an adhesion part, creating a shortcut path for the cathode foil, and the separators are fixed with the conductive polymer to reduce ESR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance from electrode foil to extraction part is increased, then the electrical resistance increases, but the ESR increases
Solution Approach 1:
A conductive polymer layer is introduced as an intermediary substance between the cathode foil and the extraction part. This conductive polymer serves as a mediator that provides a low-resistance electrical path, effectively reducing the overall ESR while maintaining the necessary structural distance for proper capacitor function.
Solution Approach 2:
The electrical conductivity parameter of the connection path is changed by applying a conductive polymer coating to the cathode foil. This parameter change transforms the high-resistance metal-to-air interface into a low-resistance conductive path, directly addressing the ESR issue without requiring structural redesign.
2Reliability
If a metal bundle is used to connect cathode foils, then electrical connection is improved, but the dielectric surface may be damaged and insulation maintenance becomes complicated
Solution Approach 1:
Instead of using a durable metal bundle that causes damage, a thin conductive polymer layer is applied. This sacrificial-like coating provides the necessary electrical connection while being soft and conformal, preventing dielectric surface damage. The conductive polymer can be easily applied and removed without causing mechanical harm.
Solution Approach 2:
The mechanical metal bundle connection system is replaced with a chemical/conductive polymer-based connection system. This substitution eliminates the mechanical pressure and potential damage caused by metal bundles while maintaining electrical connectivity through the conductive properties of the polymer layer.
3Reliability
If a metal bundle is used for cathode foil connection, then electrical conductivity is improved, but insulation maintenance becomes complicated
Solution Approach 1:
The conductive polymer is applied as a uniform, homogeneous layer across the cathode foil surface. This homogeneous coating provides consistent electrical conductivity throughout the connection area, eliminating the need for complex insulation schemes required by discrete metal bundle connections. The uniform application simplifies both the connection structure and the associated insulation requirements.
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 design achieves a significantly lower ESR by providing a direct electrical connection between cathode foils through the conductive polymer, enhancing electrical conductivity and reducing resistance.
Implementation Method 1
a conductive polymer is formed... the first separator and the second separator are at least partially fixed in a manner of being electrically connected by the conductive polymer
Implementation Method 2
an electrical resistance portion becomes a problem... achieves a significantly lower ESR by providing a direct electrical connection between cathode foils through the conductive polymer
Data Source
AI summary
A solid electrolytic capacitor includes a capacitor element in which a first separator, an anode foil connected to an extraction lead terminal and having an anodized film on a surface thereof, a second separator, and a cathode foil connected to an extraction lead terminal are sequentially disposed and in which a conductive polymer is formed, wherein the first separator and the second separator project from the anode foil in a planar direction and face each other in a manner of each having the conductive polymer, wherein the first separator and the second separator are at least partially fixed in a manner of being electrically connected by the conductive polymer, forming an adhesion part thereat.