High Voltage Electrolyte Capacitor Production via Conductive Polymer Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for producing solid electrolyte capacitors with low equivalent series resistance (ESR) and low residual current struggle to achieve high nominal voltages without compromising reliability, as the re-forming of the oxide layer becomes difficult and leads to reduced break-through voltage and reliability at higher voltages.
Innovation Solution
A process involving the use of dispersions with particles of electrically conductive polymer having an average diameter of 1 to 100 nm, which eliminates the need for re-forming the oxide film, allowing for the production of capacitors with low ESR and residual current while maintaining high nominal voltage and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If re-forming is performed below anodizing voltage to avoid ESR increase, then ESR is maintained, but the break-through voltage and reliability are reduced
Solution Approach 1:
The patent extracts the re-forming process entirely from the manufacturing sequence. By optimizing the initial anodization parameters to create an oxide layer with appropriate morphology and composition, the process eliminates the need for any subsequent re-forming step, thereby maintaining both high break-through voltage and low ESR without process complexity
Solution Approach 2:
The patent performs preliminary action by establishing the optimal oxide layer structure during the initial anodization process. The oxide layer is formed with controlled pore size, wall thickness, and crystalline structure that inherently provide both high break-through voltage and low residual current, making any subsequent re-forming unnecessary
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 process results in solid electrolyte capacitors with significantly higher break-through voltage, improved reliability, and the ability to operate at higher nominal voltages without the need for oxide layer re-forming, making them suitable for applications requiring high voltage and low ESR.
Implementation Method 1
a porous electrode body (2) of an electrode material is subjected to anodic oxidation for formation of a dielectric (3) which covers the surface of this electrode material
Implementation Method 2
a dispersion A) which comprises at least particles B) of an electrically conductive polymer and a dispersing agent D), and for the formation of a solid electrolyte (4) which completely or partly covers the dielectric surface
Data Source
AI summary
The invention relates to a process for the production of electrolyte capacitors having a low equivalent series resistance and low residual current for high nominal voltages, electrolyte capacitors produced by this process and the use of such electrolyte capacitors.