Electrolytic Capacitor Solid Layer Manufacturing
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Solution Overview
Problem
Solid electrolytic capacitors face issues with increased leak current and a higher risk of short circuits due to the low repairability of their dielectric layers when subjected to overvoltage, as they lack the ionic migration that occurs in electrolytic capacitors with liquid electrolytes.
Innovation Solution
A method for manufacturing electrolytic capacitors involving the formation of a capacitor element with an anode and cathode foil, impregnated with a dispersion solution containing electrically conductive solid particles or aggregates to create a conductive solid layer, followed by impregnation with a solvent containing no supporting salt, ensuring even layer formation and enhanced safety against overvoltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an electrically conductive solid layer containing an electrically conductive solid polymer is formed in a capacitor element, then the ESR in a high frequency range is reduced, but the leak current increases due to low repairability of the dielectric layer
Solution Approach 1:
The patent uses a composite structure combining an electrically conductive solid polymer layer with a porous layer containing electrolytic solution. The conductive polymer provides low ESR while the porous layer with electrolytic solution enables dielectric repair, thus resolving the contradiction between low ESR and low leak current.
Solution Approach 2:
The patent creates different functional zones: the electrically conductive solid polymer layer provides high conductivity for low ESR, while the porous layer provides ionic conductivity for dielectric repair. Each layer performs its specific function locally, resolving the contradiction between energy loss and reliability.
2Loss of energy
If an electrically conductive solid layer is formed by oxidative polymerization in the capacitor element, then the ESR is reduced, but the dielectric layer damage occurs due to the polymerization process
Solution Approach 1:
The patent separates the dielectric layer formation and the conductive layer formation into distinct steps. The dielectric layer is first formed on the aluminum foil, then the conductive solid polymer layer is formed separately on the dielectric layer, avoiding damage to the dielectric layer during polymerization.
Solution Approach 2:
The dielectric layer is formed in advance before the conductive solid polymer layer is applied. This preliminary formation of the dielectric layer protects it from damage during the subsequent polymerization process, while still achieving low ESR.
3Object-affected harmful factors
If a sealing body structure is used to prevent gas emission, then safety is improved, but the short circuit of the capacitor element itself cannot be prevented
Solution Approach 1:
The patent converts the potentially harmful oxidative polymerization process into a beneficial repair mechanism. The electrolytic solution in the porous layer enables oxidation reactions that repair damaged dielectric portions, transforming a harmful process into a protective mechanism against short circuits.
Solution Approach 2:
The capacitor element has self-repairing capability through the electrolytic solution in the porous layer. When the dielectric layer is damaged, the electrolytic solution enables oxidation reactions that automatically repair the damaged portions, providing self-service protection against short circuits.
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 results in capacitors with low Equivalent Series Resistance (ESR), low leak current, and high heat resistance, while preventing short circuits and ensuring safety even under overvoltage conditions by avoiding damaged dielectric layers and oxidative polymerization-related issues.
Implementation Method 1
impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive solid or aggregates thereof to form an electrically conductive solid layer having the particles of the electrically conductive solid or the aggregates thereof
Implementation Method 2
the above-mentioned polymerizable monomer is oxidatively polymerized in the inside of the capacitor element to form the electrically conductive solid layer
Implementation Method 3
the damaged portion can be repaired by oxidation reaction with oxygen generated from a supporting salt of an ionic compound in the electrolytic solution when a rated voltage is applied
Data Source
AI summary
A method for manufacturing an electrolytic capacitor including: forming a capacitor element having an anode foil and a cathode foil; impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive solid or aggregates thereof and a dispersion solvent to form an electrically conductive solid layer having the particles of the electrically conductive solid or the aggregates thereof in the capacitor element ; and impregnating the capacitor element having the electrically conductive solid layer with a solvent containing no supporting salt.