Electrode Foil Dielectric Structure for Higher Capacitor Capacitance

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Solution Overview

Problem

The natural oxide film formed on the surface of the anode body in electrolytic capacitors can reduce the electrostatic capacity due to impurities and uneven coverage.

Innovation Solution

An electrode foil with a core part and a porous part, where the porous part is covered with a first dielectric layer having varying thicknesses and a second dielectric layer containing an oxide of a second metal, is used. The first dielectric layer is partially removed using atomic layer etching or acid immersion to optimize the thickness and reduce the influence on electrostatic capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a natural oxide film is formed on the anode body surface, then the anode body is protected from further oxidation, but the electrostatic capacity is reduced due to impurities and uneven coverage

Engineering Contradiction:
Improveprotection from oxidationVSAvoidelectrostatic capacity
Core Design Contradiction:
ReliabilityVSQuantity of substance

Solution Approach 1:

The patent removes the natural oxide film that forms on the anode body surface through chemical etching or electrochemical treatment. By extracting this harmful oxide layer, the patent eliminates the source of impurities and uneven coverage that reduce electrostatic capacity, while the subsequent dielectric layer formation provides the necessary protection without the harmful effects of the natural oxide film.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent creates a controlled dielectric layer with specific local properties on the anode body surface. Instead of relying on the uniform but impure natural oxide film, the patent forms a dielectric layer with controlled thickness and composition that provides both protection and high electrostatic capacity. The etching process also creates a porous structure with different local properties that enhance capacitance.

Inventive Principle:
Principle #3Local quality

2Reliability

If the first dielectric layer is made thicker to improve coverage, then protection is enhanced, but electrostatic capacity is reduced due to increased distance between electrodes

Engineering Contradiction:
Improvecoverage and protectionVSAvoidelectrostatic capacity
Core Design Contradiction:
ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies the local quality principle by creating a porous structure in the dielectric layer with varying local thickness. The etching process generates pores that allow the dielectric material to be present in multiple locations at different distances from the electrode, providing both coverage and maintaining strong electric field interaction for high capacitance.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements a nested structure where the porous dielectric layer contains pores that are filled with electrolyte or additional dielectric material. This nested configuration allows the protection function to be maintained while the inner regions provide enhanced electrostatic capacity through the nested dielectric/electrolyte structure.

Inventive Principle:
Principle #7Nested doll (Nesting)

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 configuration enhances the electrostatic capacity of the electrolytic capacitor by minimizing the impact of the first dielectric layer and utilizing a second dielectric layer with a high relative dielectric constant to increase capacitance.

Implementation Method 1

a second step of removing at least a part of the first dielectric layer by an atomic layer etching method or acid immersion

Methodology Applied
Scientific EffectAtomic layer etching:

Implementation Method 2

a second dielectric layer covering at least a part of the first dielectric layer, the second dielectric layer containing an oxide of a second metal

Methodology Applied
Scientific EffectDielectric constant: Dielectric Permittivity

Data Source

PatentUS12327696B2Electrode foil for electrolytic capacitor, electrolytic capacitor, and method for manufacturing electrolytic capacitor
Publication Date: 2025.06.10 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD
  • US12327696B2 patent drawing
  • US12327696B2 patent drawing

AI summary

An electrode foil for an electrolytic capacitor includes: an anode body that includes a core part and a porous part disposed on a surface of the core part, and contains a first metal; a first dielectric layer that covers at least a part of the porous part; and a second dielectric layer that covers at least a part of the first dielectric layer. The second dielectric layer contains an oxide of a second metal. The first dielectric layer includes a first part having a thickness T1 and a second part having a thickness T2 smaller than the thickness T1.