Two-Layer Electrospun Fiber Film Separator for Aluminum Capacitors
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Solution Overview
Problem
Existing aluminum electrolytic capacitors face challenges in increasing capacitance while preventing short circuits, as thinner separators can lead to winding difficulties and compromised performance in breakdown voltage and electrolytic solution permeability.
Innovation Solution
A two-layer fiber film with different fiber diameters is used as a separator between the anode and cathode, where the first layer with a larger diameter provides high breakdown voltage and the second layer with a smaller diameter enhances electrolytic solution permeability, ensuring compatible performance and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thinner separator is used to increase capacitance, then the capacitance increases, but the breakdown voltage decreases and short circuit risk increases
Solution Approach 1:
The separator is divided into two distinct layers: a first layer with larger fiber diameter (3-10 μm) providing high breakdown voltage, and a second layer with smaller fiber diameter (1-5 μm) providing high electrolytic solution permeability. This segmentation allows each layer to specialize in one function, resolving the contradiction between thin separator requirements and breakdown voltage requirements.
Solution Approach 2:
The invention uses a composite structure combining two types of fibers with different properties in a single separator. The first layer uses fibers with larger diameter for electrical insulation, while the second layer uses fibers with smaller diameter for electrolyte transport. This composite approach enables the separator to simultaneously achieve high breakdown voltage and high capacitance.
2Quantity of substance
If a thinner separator is used to increase capacitance, then the capacitance increases, but electrolytic solution permeability decreases
Solution Approach 1:
The separator is divided into two distinct layers: a first layer with larger fiber diameter (3-10 μm) providing high breakdown voltage, and a second layer with smaller fiber diameter (1-5 μm) providing high electrolytic solution permeability. This segmentation allows each layer to specialize in one function, resolving the contradiction between thin separator requirements and breakdown voltage requirements.
Solution Approach 2:
Different regions of the separator (first layer vs. second layer) have different fiber diameters tailored to their specific functions. The first layer near the dielectric layer has larger fibers for insulation, while the second layer has smaller fibers for electrolyte permeability. This local quality differentiation resolves the contradiction between capacitance and permeability.
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 allows for increased capacitance while maintaining high breakdown voltage and efficient electrolytic solution permeability, effectively suppressing short circuits and improving the overall performance of the aluminum electrolytic capacitor.
Implementation Method 1
a fiber film forming section that forms a fiber film by ejecting fibers from a nozzle in an electrospinning manner
Data Source
AI summary
According to one embodiment, an aluminum electrolytic capacitor includes an anode, a cathode, and a fiber film. The anode includes a first metal layer and a dielectric layer. The first metal layer includes aluminum. The dielectric layer is formed on the first metal layer. The cathode includes a second metal layer. The second metal layer includes aluminum. The fiber film is provided between the anode and the cathode. The fiber film includes a first layer and a second layer. The first layer includes a first fiber having a first diameter. The first layer is provided between the dielectric layer and the second layer. The second layer includes a second fiber having a second diameter smaller than the first diameter.