Hybrid Capacitor Pre-Treated Conductive Polymer Separator
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Solution Overview
Problem
Existing methods for forming hybrid capacitors are limited in size and unsuitable for manufacturing large or axial capacitors, due to issues with polymer diffusion and separator filtration, resulting in restricted capacitance and high Equivalent Series Resistance (ESR).
Innovation Solution
The method involves pre-treating anodes, cathodes, and separators with conductive polymer coatings before winding, forming a conductive porous layer that allows liquid electrolyte to flow freely, eliminating size restrictions and enhancing capacitance and ESR performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-formed conductive polymer slurry is used to impregnate the interstitial spaces of the capacitor winding, then the ESR is reduced, but the capacitor size is limited to small dimensions due to diffusion limitations
Solution Approach 1:
The conductive polymer is applied to the separator and electrode surfaces before the winding process, rather than attempting to diffuse it into the completed winding. This preliminary application ensures complete coverage of all surfaces including interstitial areas, eliminating the diffusion limitation that restricts capacitor size in conventional methods
Solution Approach 2:
The separator is made porous to allow free flow of liquid electrolyte while providing a substrate for conductive polymer coating. The porous structure enables both small and large capacitor configurations to achieve proper polymer coverage and electrolyte penetration, resolving the size limitation issue
2Ease of manufacture
If the separator filters polymeric particles and counterions, then the polymer slurry can be applied, but the diffusion into interstitial spaces is limited, restricting effective capacitor length
Solution Approach 1:
The conductive polymer is applied to the separator and electrode surfaces before the winding process, rather than attempting to diffuse it into the completed winding. This preliminary application ensures complete coverage of all surfaces including interstitial areas, eliminating the diffusion limitation that restricts capacitor size in conventional methods
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 approach enables the production of capacitors with improved quality and reproducibility, achieving high capacitance and low ESR without size limitations, suitable for various designs including axial capacitors, with enhanced volumetric efficiency and self-healing capabilities.
Implementation Method 1
The separator is impregnated with conductive polymer or coated with conductive polymer on at least one surface... The conductive polymer particles and counterions are not substantially filtered by the separator... allowing liquid electrolyte to flow freely
Implementation Method 2
conductive polymers have a high conductivity, up to 600 S/cm, and therefore capacitors utilizing conductive polymeric cathodes have a much lower ESR
Implementation Method 3
The anode, cathode and separator are wound together to form a working element... The anode, cathode and separator are wound together in any suitable configuration
Data Source
Figure 1~2
Figure 3
Figure 4A~4C
AI summary
The capacitor comprises a working element (402, 44) wherein the working element (402, 44) comprises an anode comprising a dielectric thereon and an anode conductive polymer layer (212) on the dielectric. The capacitor also includes a cathode (114) comprising a cathode conductive polymer layer (214) and a conductive separator (16) between the anode and said cathode (114). An anode lead (20) is in electrical contact with the anode and a cathode lead (22) is in electrical contact with the cathode (114).