Electrolytic Capacitor Solid Electrolyte Layer ESR Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing electrolytic capacitors with solid electrolyte layers fail to adequately reduce equivalent series resistance (ESR) despite the use of additives in the solid electrolyte layer.
Innovation Solution
A method involving a first treatment solution of conductive polymer dissolved or dispersed in a liquid component, left to stand for a specific period, then mixed with a second component before applying it to a dielectric layer to form a solid electrolyte layer, where the standing time is longer than the mixing period, optimizing the formation of a low ESR electrolytic capacitor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additives are blended into the solid electrolyte layer, then coating property and adhesion are improved, but ESR reduction effect is insufficient
Solution Approach 1:
The conductive polymer solution is left to stand for a predetermined period before applying to the dielectric layer, allowing the polymer chains to orient and form a more effective conductive network structure in advance, which enhances ESR reduction while maintaining good adhesion
Solution Approach 2:
The patent changes the temporal parameter by introducing a standing period between solution preparation and application, transforming the solution's internal structure over time to achieve optimal ESR reduction properties
2Productivity
If conductive polymer solution is applied immediately after preparation, then productivity is improved, but ESR and coating uniformity are insufficient
Solution Approach 1:
The solution undergoes a preliminary standing period that prepares the conductive polymer structure in advance, ensuring uniform coating properties and low ESR before the actual application step, thereby achieving both quality and efficiency
3Reliability
If standing period is extended, then ESR is reduced and coating property is improved, but manufacturing time increases
Solution Approach 1:
The patent optimizes the standing time parameter to achieve the minimum effective duration required for ESR reduction, balancing the trade-off between quality improvement and manufacturing time efficiency
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 effectively reduces ESR in electrolytic capacitors by stabilizing the conductive polymer solution, improving coating properties and adhesion, leading to a more uniform solid electrolyte layer and enhanced capacitor performance.
Implementation Method 1
dissolving or dispersing a conductive polymer in a liquid first component
Implementation Method 2
dissolving or dispersing a conductive polymer in a liquid first component
Implementation Method 3
leaving a conductive polymer solution or a conductive polymer dispersion liquid to stand for a first period
Implementation Method 4
forming a solid electrolyte layer on a surface of the dielectric layer by applying the second treatment solution to the surface of the dielectric layer
Data Source
AI summary
A method for manufacturing an electrolytic capacitor according to the present disclosure includes a first step to a third step described below. The electrolytic capacitor includes an anode body having a dielectric layer, and a solid electrolyte layer formed on a surface of the dielectric layer. The first step is a step of preparing a first treatment solution by dissolving or dispersing a conductive polymer in a liquid first component and leaving a conductive polymer solution or a conductive polymer dispersion liquid to stand for a first period. The second step is a step of preparing a second treatment solution by mixing the first treatment solution with a second component. The third step is a step of forming a solid electrolyte layer on a surface of the dielectric layer by applying the second treatment solution to the surface of the dielectric layer.