Electrolytic Capacitor Volume Ratio Optimization
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Solution Overview
Problem
Conventional electrolytic capacitors with solid electrolytes and electrolytic solutions have not optimized characteristics, particularly in terms of capacitance, equivalent series resistance (ESR), and reliability, due to complex manufacturing processes and inefficient use of volume ratios between the electrolytic solution and solid electrolyte layer.
Innovation Solution
The electrolytic capacitor incorporates a solid electrolyte layer formed by impregnating a dispersion liquid with conductive polymer particles or dissolved conductive polymers into the winding body, followed by drying, and then impregnating a non-aqueous electrolytic solution with a specific volume ratio to the solid electrolyte layer, optimizing the volume ratios to enhance electrical characteristics and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a winding body is impregnated with a polymerization solution to form a solid electrolyte layer, then a conductive polymer layer is formed in the winding body, but the manufacturing process becomes complicated
Solution Approach 1:
The patent extracts the polymerization step from the manufacturing process by using pre-formed conductive polymer particles or dissolved conductive polymer in a dispersion liquid or solution, eliminating the need for in-situ polymerization and simplifying the overall manufacturing process while still achieving reliable solid electrolyte layer formation
Solution Approach 2:
The conductive polymer is prepared in advance as particles or dissolved in a solvent before impregnation, rather than forming it during the manufacturing process. This preliminary preparation simplifies the manufacturing process by separating the polymerization step from the capacitor assembly process
2Reliability
If the volume ratio of electrolytic solution to solid electrolyte layer is not optimized, then manufacturing is simpler, but capacitance retention and ESR characteristics are poor
Solution Approach 1:
The patent specifies precise parameter ranges for the volume ratio of electrolytic solution to solid electrolyte layer (1.27 to 2.54) and void volume ratio (0.04 to 0.38), transforming the optimization problem into a controlled parameter specification that ensures desired electrical characteristics without requiring complex manufacturing adjustments
Solution Approach 2:
The patent allows for a specific range of electrolytic solution volume (excessive amount within controlled limits) to ensure adequate wetting and electrical contact, while also specifying minimum void space to prevent excessive pressure and potential leakage, achieving optimal characteristics through controlled excess rather than precise minimal dosing
3Reliability
If a winding body is impregnated with both dispersion liquid and electrolytic solution, then electrical characteristics improve, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the impregnation of conductive polymer (from dispersion liquid or solution) with the subsequent impregnation of electrolytic solution into a streamlined sequential process, where the first impregnation creates the solid electrolyte layer and the second impregnation fills remaining spaces, achieving both electrical characteristics improvement and manufacturing efficiency
Solution Approach 2:
The solid electrolyte layer is formed in advance through the first impregnation and drying step, creating a stable foundation that enables the second electrolytic solution impregnation to proceed efficiently without requiring re-optimization of the conductive polymer distribution, thus improving overall manufacturing productivity
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 optimized volume ratios of the electrolytic solution to the solid electrolyte layer and voids within the capacitor improve capacitance retention, reduce ESR, enhance voltage resistance, and prevent liquid leakage, while ensuring necessary volumes for desired electrical characteristics.
Implementation Method 1
a winding body is impregnated with a dispersion liquid in which particles of a conductive polymer are dispersed or a solution in which a conductive polymer is dissolved, to infiltrate the dispersion liquid or the solution into a gap present in the winding body
Implementation Method 2
drying is conducted to dry the dispersion liquid or the solution impregnated into the winding body
Implementation Method 3
an electrolytic solution is impregnated into the winding body in which the solid electrolyte layer is formed
Data Source
AI summary
An electrolytic capacitor includes a capacitor element. The capacitor element includes a winding body, a solid electrolyte layer containing a conductive polymer, and an electrolytic solution. The winding body is configured to be wound around by an anode member on which a dielectric layer is formed, and a cathode member. The solid electrolyte layer is formed in the winding body. An electrolytic solution is impregnated into the winding body in which the solid electrolyte layer is formed. A volume ratio of the electrolytic solution impregnated into the winding body to the solid electrolyte layer formed in the winding body ranges from 1.27 to 2.54 both inclusive.