Dual-Layer Conductive Polymer Electrolyte for Low-Leakage Capacitors
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Solution Overview
Problem
There is a need to improve the characteristics and reliability of solid electrolytic capacitors, specifically in reducing leakage current, improving voltage resistance, and enhancing overall performance.
Innovation Solution
A manufacturing method for solid electrolytic capacitors involves forming a first solid electrolyte layer with a conductive polymer derived from a monomer containing an alkyl EDOT compound, and a second solid electrolyte layer, both of which include silicon-containing components, to achieve improved electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer solid electrolyte is formed on the dielectric layer, then the manufacturing process is simple, but the leakage current is high and voltage resistance is poor
Solution Approach 1:
The solid electrolyte layer is divided into two distinct layers: a first solid electrolyte layer containing a conductive polymer formed by polymerizing a monomer with an oxidizing agent, and a second solid electrolyte layer containing a different conductive polymer. This segmentation allows each layer to perform specific functions, with the first layer providing good interface contact and the second layer providing high conductivity and voltage resistance, thereby reducing leakage current while maintaining manufacturing feasibility.
Solution Approach 2:
The invention uses composite materials by combining two different conductive polymers in separate layers. The first conductive polymer is formed from a monomer polymerized with an oxidizing agent, while the second conductive polymer has different properties. This composite structure leverages the advantages of each material to achieve both low leakage current and high voltage resistance, resolving the contradiction between reliability improvement and device complexity.
2Reliability
If the solid electrolyte layer is made thicker to improve voltage resistance, then the withstand voltage increases, but the manufacturing precision and uniformity decrease
Solution Approach 1:
Instead of forming a single thick electrolyte layer which is difficult to control uniformly, the invention segments the electrolyte into two thinner layers. Each layer can be formed with better uniformity and precision, while collectively providing the required total thickness for voltage resistance. This approach maintains manufacturing precision while achieving the desired reliability improvement.
3Reliability
If a conductive polymer is formed by polymerizing monomer with oxidizing agent, then the capacitance improves, but the leakage current may increase without proper layer configuration
Solution Approach 1:
The invention uses a composite structure where the first solid electrolyte layer (formed by polymerizing monomer with oxidizing agent) provides high capacitance, while the second solid electrolyte layer with different conductive polymer properties provides low leakage current. This composite material approach allows both high capacitance and low leakage current to be achieved simultaneously, resolving the contradiction between these two parameters.
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 proposed method results in solid electrolytic capacitors with reduced leakage current, increased withstand voltage, and improved capacitance, thereby enhancing the overall performance and reliability of the capacitors.
Implementation Method 1
a step (i-b) of forming the first solid electrolyte layer by polymerizing the monomer in the supplied reaction solution to form the first conductive polymer
Implementation Method 2
The first solid electrolyte layer contains a first conductive polymer and a silicon-containing component
Data Source
AI summary
A solid electrolytic capacitor that includes an anode body having a porous part on surface thereof and a manufacturing method thereof including a step (i) of forming a first solid electrolyte layer on a dielectric layer and a step (ii) of forming a second solid electrolyte layer on the first solid electrolyte layer. The first and second solid electrolyte layers contain first and second conductive polymers, respectively. The step (i) includes a step (i-a) of supplying a reaction solution containing a monomer and a silane compound to the surface of the dielectric layer, and a step (i-b) of forming the first solid electrolyte layer by polymerizing the monomer in the supplied reaction solution to form the first conductive polymer. The monomer contains a compound represented by the following formula (I) (in the formula (I), R represents an alkyl group whose carbon number is within a range of 1 to 10).