Electro-polymerized Coating for Wet Electrolytic Capacitor
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Solution Overview
Problem
Existing wet electrolytic capacitors face challenges with the detachment of expensive conductive coatings and reduced mechanical stability, which affects their performance and reliability.
Innovation Solution
A wet electrolytic capacitor design featuring a conductive coating with a discontinuous precoat layer and a conductive polymer layer formed through anodic electrochemical polymerization, providing enhanced surface coverage and mechanical stability by using a colloidal suspension of precursor monomers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conductive coating is applied to enhance capacitance, then capacitance is improved, but the coating becomes easily detached and mechanical stability deteriorates
Solution Approach 1:
The conductive coating is divided into multiple discrete projections rather than a continuous layer. These spaced-apart projections cover 5-80% of the substrate surface, creating a segmented structure that maintains capacitance while improving mechanical stability and reducing detachment issues
Solution Approach 2:
The coating transitions from a uniform continuous layer to a non-uniform distribution of discrete projections with varying sizes and spacing. This local variation in coating density and morphology optimizes both electrical performance (capacitance) and mechanical properties (adhesion and stability) in different regions
2Area of stationary object
If a continuous conductive coating is applied, then surface coverage is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of applying a continuous coating layer, the method uses discrete conductive projections that are simpler to manufacture. The projections are formed through a straightforward process of applying conductive material that naturally forms discrete structures, avoiding the complexity of creating and maintaining continuous uniform coatings
Solution Approach 2:
The discrete projections use less conductive material compared to continuous coatings, reducing material costs. The simplified formation process and reduced material requirements make this a more economical approach while achieving sufficient surface coverage for capacitor function
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 solution improves the adhesion and conductivity of the coating, reducing equivalent series resistance (ESR) and enhancing capacitance, while maintaining electrical performance and stability over time.
Implementation Method 1
The coating also contains a conductive polymer layer that overlies the discontinuous precoat layer, wherein the conductive polymer layer is formed by electrolytic polymerization of a colloidal suspension that includes a precursor monomer
Implementation Method 2
An electrode is placed in contact with the metal substrate, and a current feed is supplied to the electrode to induce electrolysis and oxidative polymerization of the precursor monomer
Implementation Method 3
a current feed is supplied to the electrode to induce electrolysis and oxidative polymerization of the precursor monomer, thereby forming a conductive polymer layer
Data Source
AI summary
A wet electrolytic capacitor that contains a casing within which is positioned an anode formed from an anodically oxidized sintered porous body and a fluidic working electrolyte is provided. The casing contains a conductive coating disposed on a surface of a metal substrate. The casing contains a metal substrate coated with a conductive coating. The conductive coating contains a conductive polymer layer formed through anodic electrochemical polymerization (“electro-polymerization”) of a colloidal suspension on the surface of the metal substrate. The conductive coating also contains a precoat layer that is discontinuous in nature and contains a plurality of discrete projections of a conductive material that are deposited over the surface of the metal substrate in a spaced-apart fashion so that they form “island-like” structures.