Electrolytic Capacitor Silane Interlayer ESR Reduction
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Solution Overview
Problem
Existing electrolytic capacitors face challenges in reducing equivalent series resistance (ESR) while maintaining conductivity and adhesion between conductive polymer layers, which affects their performance.
Innovation Solution
The electrolytic capacitor design includes a first conductive polymer layer with a silane compound and a second conductive polymer layer containing a basic compound, which enhances adhesion and reduces ESR by suppressing dedoping of the dopant, thereby improving both conductivity and withstand voltage characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a layer of amine compound is provided between conductive polymer layers to improve adhesion, then adhesion between layers is improved, but conductivity of the conductive polymer layer is lowered and ESR is increased
Solution Approach 1:
The patent introduces a silane compound layer as an intermediary between the first and second conductive polymer layers. This silane layer serves as a mediator that provides both adhesion promotion and maintains electrical conductivity, resolving the contradiction by finding a middle-ground material that fulfills both requirements simultaneously rather than using amine compounds that sacrifice conductivity for adhesion.
Solution Approach 2:
The patent changes the chemical composition and properties of the intermediate layer from amine compounds to silane compounds. This parameter change in the intermediate layer's chemical structure allows it to provide adhesion while maintaining conductivity, thereby reducing ESR while improving inter-layer adhesion.
2Quantity of substance
If multiple conductive polymer layers are formed to improve performance, then capacitance and coverage are improved, but ESR reduction becomes more difficult to achieve
Solution Approach 1:
The patent creates a composite structure consisting of multiple conductive polymer layers with different compositions. The first conductive polymer layer contains a first dopant, while the second conductive polymer layer contains a second dopant and basic compound. This composite multi-layer structure achieves both high capacitance and low ESR by optimizing each layer's function.
Solution Approach 2:
The patent applies local quality by giving different regions (layers) different compositions and functions. The first conductive polymer layer is optimized for one function while the second conductive polymer layer is optimized for another function, allowing the overall structure to achieve both high capacitance and low ESR simultaneously.
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 reduces ESR and enhances the capacitors' performance by improving adhesion and coverage between layers, leading to better electrical characteristics and reliability.
Implementation Method 1
a first conductive polymer layer which includes a first layer and a second layer, the first layer contains a first conductive polymer and a first dopant and covers at least a part of the dielectric layer, the second layer is formed on the first layer and contains a first silane compound
Implementation Method 2
The second conductive polymer layer contains a second conductive polymer, a second dopant, and a basic compound
Data Source
AI summary
An electrolytic capacitor includes: an anode body; a dielectric layer formed on the anode body; a first conductive polymer layer which covers at least a portion of the dielectric layer; and a second conductive polymer layer which covers at least a portion of the first conductive polymer layer. The first conductive polymer layer includes a first layer and a second layer. The first layer contains a first conductive polymer and a first dopant, and covers at least a portion of the dielectric layer. The second layer is formed on the first layer, and contains a first silane compound. The second conductive polymer layer contains a second conductive polymer, a second dopant, and a basic compound.