Composite Powder Coating for Stable Electrolytic Capacitor Anodes
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Solution Overview
Problem
Existing methods for producing porous bodies in electrolytic capacitors result in high carbon content and mass variation, leading to increased leakage current and capacitance variation, which affects the reliability and productivity of the capacitors.
Innovation Solution
A composite powder is used, comprising a valve metal powder coated with an alcohol compound having a melting point of 35°C or higher, which improves weighing stability and reduces carbon content, thereby minimizing mass variation and leakage current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional binders (acrylic polymer, camphor, dimethyl sulfone) are used in the raw material powder, then the powder can be aggregated and molded, but the carbon content in the porous body increases and mass variation occurs
Solution Approach 1:
The patent changes the chemical composition parameter of the binder from conventional organic binders (acrylic polymer, camphor, dimethyl sulfone) to a carboxylic acid binder. This parameter change eliminates carbon contamination while maintaining the binder's essential function of aggregating powder particles and enabling molding, thus resolving the contradiction between ease of manufacture and carbon content control.
2Ease of manufacture
If conventional binders are used, then the powder can be molded, but mass variation and leakage current increase occur
Solution Approach 1:
The patent changes the chemical parameter of the binder to carboxylic acid, which has superior properties compared to conventional binders. This parameter change ensures uniform distribution in the powder, consistent molding characteristics, and elimination of mass variation, thereby improving reliability while maintaining molding capability.
3Ease of manufacture
If polymer binders are used, then powder aggregation is achieved, but the binder residue affects product purity and performance
Solution Approach 1:
The patent changes the binder type from polymer to carboxylic acid compound. This parameter change allows the binder to fulfill its aggregation function during manufacturing while being completely removable without residue in the final sintered product, thus eliminating the contradiction between aggregation capability and product purity.
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 method reduces carbon content and mass variation, enhancing the reliability and productivity of electrolytic capacitors by stabilizing the powder composition and reducing leakage current.
Implementation Method 1
an alcohol compound (excluding a polymer) adhering to surfaces of particles of the raw material powder
Implementation Method 2
removing the solvent by drying the raw material powder in the wet state while stirring the raw material powder
Data Source
AI summary
A composite powder for manufacturing a porous body included in an anode body of an electrolytic capacitor contains a raw material powder containing a valve metal and an alcohol compound (excluding a polymer) adhering to surfaces of particles of the raw material powder. A melting point of the alcohol compound is more than or equal to 35° C.