Electrolytic Capacitor Solid Electrolyte Withstand Voltage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods fail to sufficiently improve the withstand voltage characteristics of electrolytic capacitors, which are crucial for high-frequency applications in digital electronic devices.
Innovation Solution
The manufacturing process involves forming a solid electrolyte layer on an anode member using a conductive polymer, specifically a polymer of a monomer represented by formula (I) with an alkyl group, and a silicon-containing component derived from a silane compound, enhancing the capacitor's withstand voltage by improving insulation and adhesion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid electrolyte layer using conventional conductive polymers is provided, then low ESR can be achieved, but withstand voltage characteristics are insufficient
Solution Approach 1:
The patent uses a composite material consisting of conductive polymer particles dispersed in a silane compound matrix. The silane compound forms an insulating barrier that blocks leakage current paths while the conductive polymer particles maintain low ESR. This composite structure resolves the contradiction between achieving low ESR and improving withstand voltage characteristics by combining materials with complementary properties.
Solution Approach 2:
The patent changes the chemical and physical parameters of the solid electrolyte layer by incorporating silane compounds with specific functional groups and controlling the dispersion state of conductive polymer particles. This parameter modification enables the layer to simultaneously achieve high insulation performance for withstand voltage and sufficient conductivity for low ESR.
2Reliability
If the solid electrolyte layer is made more insulating to improve withstand voltage, then leakage current is suppressed, but ESR increases
Solution Approach 1:
The composite structure of conductive polymer particles in a silane compound matrix allows simultaneous optimization of insulation and conductivity. The silane compound provides the insulating matrix for high withstand voltage, while the dispersed conductive polymer particles create conductive pathways that maintain low ESR, resolving the contradiction between insulation and resistance.
Solution Approach 2:
The solid electrolyte layer exhibits local quality variation where the silane compound provides insulation in the matrix regions while conductive polymer particles provide conductivity in dispersed regions. This spatial distribution of different functional properties enables the layer to simultaneously achieve high withstand voltage and low ESR.
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 approach results in electrolytic capacitors with significantly improved withstand voltage characteristics, reduced equivalent series resistance (ESR), and suppressed leakage current, making them suitable for high-frequency digital applications.
Implementation Method 1
forming a solid electrolyte layer including a conductive polymer including a polymer of the monomer and a silicon-containing component derived from the silane compound
Implementation Method 2
significantly low ESR of a solid electrolytic capacitor can be achieved by providing a solid electrolyte layer using poly(3,4-ethylenedioxythiophene) (hereinafter, referred to as 'PEDOT') having extremely high electric conductivity
Implementation Method 3
an anode foil having a dielectric layer and a solid electrolyte layer
Data Source
AI summary
A method for manufacturing an electrolytic capacitor of the present disclosure includes: preparing an anode member having a dielectric layer; then, impregnating the anode member with a monomer, an oxidant, a silane compound, and a solvent; and then forming a solid electrolyte layer including a conductive polymer containing a polymer of the monomer and a silicon-containing component derived from the silane compound on the surface of the dielectric layer. The above-mentioned monomer contains a compound represented by formula (I):(wherein R represents an alkyl group having 1 to 10 carbon atoms).