Colloidal Particle Coating for Solid Electrolytic Capacitor Delamination
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Solution Overview
Problem
Conventional solid electrolytic capacitors face challenges in achieving good mechanical robustness and electrical performance due to difficulties in forming a thick solid electrolyte layer, which can delaminate during encapsulation, affecting electrical performance and being costly to produce.
Innovation Solution
A solid electrolytic capacitor design that includes a colloidal particle coating formed from a colloidal dispersion of conductive polymer and latex polymer, applied over a solid electrolyte, enhancing mechanical stability and dispersibility in aqueous mediums.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick solid electrolyte layer is formed to achieve good mechanical robustness and electrical performance, then the mechanical robustness and electrical performance improve, but the production cost increases and the layer is difficult to form
Solution Approach 1:
The patent applies composite materials by combining conductive polymer particles with latex polymer particles in a colloidal dispersion. The latex polymer acts as a binder that holds the conductive polymer particles together, forming a composite coating that provides both electrical conductivity and mechanical robustness. This composite structure allows the formation of thick, stable electrolyte layers without requiring prohibitively complex or expensive manufacturing processes.
Solution Approach 2:
The patent changes the physical and chemical parameters of the electrolyte formation process by using a colloidal dispersion system. Instead of forming the electrolyte layer through traditional sequential dipping into separate monomer and catalyst solutions, the invention applies a pre-formed colloidal dispersion containing both conductive polymer particles and latex polymer particles. This parameter change simplifies the manufacturing process while enabling the formation of thick, adherent electrolyte layers with good mechanical properties.
2Strength
If a polymeric outer layer is applied to cover the solid electrolyte surface, then mechanical protection is improved, but adhesion to the graphite/silver layer deteriorates
Solution Approach 1:
The patent uses composite materials by integrating the protective and conductive functions into a single colloidal particle coating. The latex polymer provides mechanical protection and structural integrity, while the conductive polymer particles embedded within the latex matrix provide electrical conductivity and adhesion to the underlying graphite/silver layer. This composite structure eliminates the need for a separate polymeric outer layer that would compromise adhesion.
Solution Approach 2:
The colloidal particle coating performs multiple functions simultaneously: it provides mechanical protection like an outer layer, maintains electrical conductivity like a conductive polymer layer, and ensures adhesion to the graphite/silver termination. By combining these functions into a single coating applied from colloidal dispersion, the invention avoids the adhesion problems associated with separate polymeric protective layers.
3Ease of manufacture
If traditional conductive polymer electrolyte is formed through sequential dipping, then the electrolyte layer can be applied, but delamination during encapsulation occurs adversely impacting electrical performance
Solution Approach 1:
The patent applies composite materials by forming the electrolyte layer from colloidal particles consisting of conductive polymer particles dispersed in a latex polymer matrix. The latex polymer acts as a cohesive binder that prevents delamination during encapsulation, while the conductive polymer particles maintain electrical conductivity. This composite structure provides both ease of application and resistance to delamination.
Solution Approach 2:
The patent changes the physical state and composition parameters of the electrolyte layer by using a colloidal dispersion system. The electrolyte is applied as a stable colloidal suspension of particles rather than through sequential dipping of separate solutions. After application and drying, the colloidal particles form a cohesive, delamination-resistant film that maintains electrical performance, eliminating the adhesion and delamination problems of traditional sequential dipping methods.
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 colloidal particle coating improves mechanical robustness and electrical performance by stabilizing the capacitor during encapsulation and allowing for better dispersion in aqueous applications, addressing the limitations of traditional methods.
Implementation Method 1
The coating is formed from a colloidal dispersion of particles that contain at least one conductive polymer and at least one latex polymer
Implementation Method 2
a dielectric overlying the anode body
Implementation Method 3
The solid electrolyte layer may be formed from a conductive polymer (e.g., poly(3,4-ethylenedioxythiophene))
Data Source
AI summary
A solid electrolytic capacitor that includes an anode body, a dielectric overlying the anode body, a solid electrolyte overlying the dielectric, and a colloidal particle coating that overlies the solid electrolyte. The coating is formed from a colloidal particle dispersion. The particles of the dispersion contain at least two different polymer components—i.e., a conductive polymer and a latex polymer. One benefit of such a coating is that the presence of the latex polymer can help mechanically stabilize the capacitor during encapsulation due to its relatively soft nature. This helps limit delamination of the solid electrolyte and any other damage that may otherwise occur during formation of the capacitor. Furthermore, the latex polymer can also enhance the ability of the particles to be dispersed in an aqueous medium, which is desirable in various applications.