Conductive Polymer Solution for Low ESR Capacitors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional capacitor production methods require multiple steps and different treatment solutions for forming conductive polymer layers, making them time-consuming and complex, while also struggling to achieve low equivalent series resistance (ESR) and high capacitance.
Innovation Solution
A conductive polymer solution comprising a pi-conjugated conductive polymer, a polyanion, and a compound formed by reacting an oxirane or oxetane group with an anion, which is used to form a solid electrolyte layer without the need for separate inside and outside conductive polymer layer formations, allowing for a single-step process that adjusts the pH to a range of 2.0-6.0.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple treatment solutions and steps are used to form conductive polymer layers, then long-term reliability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines the formation of inside and outside conductive polymer layers into a single treatment step using one polymerization solution. The solution contains both water-soluble polymer and colloidal silica, enabling simultaneous formation of both layers with different properties through a unified process, thereby reducing manufacturing complexity while maintaining reliability
Solution Approach 2:
The polymerization solution serves multiple functions: it forms the inside conductive polymer layer, forms the outside protective layer, provides adhesion between layers, and controls pH. This multi-functionality eliminates the need for separate treatment solutions and steps, reducing process complexity while ensuring reliable capacitor performance
2Manufacturing precision
If multiple treatment solutions and steps are used to form conductive polymer layers, then layer quality is improved, but productivity decreases
Solution Approach 1:
The patent enables continuous formation of both inside and outside conductive polymer layers in a single uninterrupted polymerization step. The reaction proceeds continuously without intermediate drying or re-wetting steps, maintaining layer quality while significantly improving production efficiency and throughput
Solution Approach 2:
By merging the formation processes of inside and outside layers into one simultaneous operation, the patent eliminates sequential processing steps, reducing total manufacturing time and increasing productivity while maintaining the quality requirements for both layers
3Ease of manufacture
If strong acid is used in conductive polymer solution, then polymerization is improved, but anode damage occurs
Solution Approach 1:
The patent introduces colloidal silica as an intermediary substance that mediates between the acidic polymerization environment and the anode. The silica particles form a protective colloidal structure that allows polymerization to proceed while preventing direct contact between strong acid and the anode surface, thus preventing damage
Solution Approach 2:
The patent changes the physical state and distribution of acid in the solution by incorporating it into a colloidal system with silica. This transforms the acid from a free strong acid that damages the anode into a controlled component within the colloidal structure, maintaining polymerization efficiency while reducing harmful effects on the anode
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 enables the production of capacitors with low ESR and high capacitance while maintaining long-term reliability, simplifying the production process and eliminating the need for multiple treatment solutions.
Implementation Method 1
a pi-conjugated conductive polymer, a polyanion with which the pi-conjugated conductive polymer is doped
Implementation Method 2
a conductive film containing a pi-conjugated conductive polymer may be used as the solid electrolyte layer
Implementation Method 3
a compound formed by reacting an oxirane or oxetane group with an anion
Data Source
AI summary
[Object] To provide a conductive polymer solution capable of forming a capacitor having a large capacitance, low ESR, and excellent long-term reliability without using treatment solutions for conductive polymer layer formation differing in composition, and without forming an inside conductive polymer layer by different approaches, the capacitor and a method for producing the capacitor [Solution] The present invention relates to: a conductive polymer solution which comprises a conductive polymer and a solvent, wherein the conductive polymer comprises a pi-conjugated conductive polymer, a polyanion with which the pi-conjugated conductive polymer has been doped, and a compound formed by reacting an oxirane or oxetane group with an anion making no contribution to the dope in the polyanion, and the solution has a pH in the range of 2.0 to 6.0; a capacitor which includes either the conductive polymer solution or the compounds remaining after removal of the solvent from the solution; and a method for producing a capacitor, comprising impregnating the capacitor with the conductive polymer solution and removing the solvent therefrom.