Hydrated Oxide Anode for Solid Electrolytic Capacitors
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Solution Overview
Problem
Conventional solid electrolytic capacitors face challenges in achieving high withstand voltage and reliability due to the complexity of anodic oxidation processes, which result in non-uniform anodic oxide films and increased leakage current, especially when cut and re-treated, leading to reduced performance and reliability.
Innovation Solution
A solid electrolytic capacitor with an anode element featuring a coating layer composed of hydrated oxide or hydroxide, formed through methods like heating in deionized water or cathodic electrolysis, which simplifies the manufacturing process and eliminates the need for conventional anodic oxidation, allowing for a non-barrier-type dielectric structure that enhances withstand voltage and reduces leakage current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional anodic oxidation is used to form a thick anodic oxide film to increase withstand voltage, then the withstand voltage increases, but the leakage current increases and the film becomes non-uniform
Solution Approach 1:
The patent changes the fundamental parameter of dielectric formation from anodic oxidation to cathodic electrolysis. This parameter change enables formation of uniform dielectric films with high withstand voltage while maintaining low leakage current, resolving the contradiction between voltage strength and reliability.
Solution Approach 2:
The patent substitutes the anodic oxidation process with a cathodic electrolysis process. This replacement of the formation mechanism allows for better control of dielectric uniformity and reduces leakage current while achieving the desired withstand voltage levels.
2Reliability
If conventional anodic oxidation is used to form the dielectric layer, then the process is well-established, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent extracts and eliminates the complicated multi-step anodic oxidation process, replacing it with a simpler cathodic electrolysis method. This extraction of unnecessary complexity improves manufacturing efficiency while maintaining process stability through the more controllable cathodic process.
Solution Approach 2:
The patent inverts the conventional approach by using cathodic electrolysis instead of anodic oxidation for dielectric formation. This inversion simplifies the manufacturing process and reduces formation time while maintaining or improving the quality and stability of the dielectric layer.
3Ease of repair
If the anode element is cut and re-treated to repair the end face, then the damaged area can be repaired, but the Vt withstand voltage of the repaired film cannot be equivalent to the original film
Solution Approach 1:
The patent replaces anodic oxidation with cathodic electrolysis for dielectric formation, which enables uniform repair films to be deposited on cut surfaces. This substitution allows the repaired areas to achieve the same Vt withstand voltage as the original film, ensuring manufacturing precision and uniformity.
Solution Approach 2:
The cathodic electrolysis process allows for preliminary formation of uniform dielectric layers that can be consistently applied to both original and repaired surfaces. This preliminary action ensures that repair areas achieve equivalent withstand voltage characteristics to the original film from the start.
4Strength
If a high formation voltage is applied to increase the thickness of the anodic oxide film, then the withstand voltage increases, but the leakage current increases and the process consumes large electric power
Solution Approach 1:
The patent substitutes anodic oxidation with cathodic electrolysis, which enables formation of thick dielectric films with high withstand voltage at lower formation voltages. This substitution dramatically reduces electric power consumption during the formation process while achieving the same or better withstand voltage performance.
Solution Approach 2:
The patent changes the formation mechanism parameter from anodic oxidation to cathodic electrolysis, which fundamentally alters the voltage-thickness relationship. This parameter change allows for efficient formation of thick dielectric layers with high withstand voltage at lower power consumption levels.
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 provides a high-quality dielectric layer that improves the withstand voltage of solid electrolytic capacitors beyond conventional limits, simplifies manufacturing, and enhances reliability by eliminating burdensome re-treatment steps, while allowing for a more flexible selection of dielectric types and formation methods.
Implementation Method 1
the step of forming the coating layer on the surface of the metal by heating the metal in deionized water or in an aqueous solution containing a hydration accelerator agent
Implementation Method 2
by subjecting the metal to deionized water steaming treatment
Implementation Method 3
by subjecting the metal to cathodic electrolysis in an aqueous solution containing phosphoric acid or a salt thereof, or silicic acid or a salt thereof
Data Source
AI summary
An anode element of a solid electrolytic capacitor and a method of fabricating the anode element are improved, so that the step of manufacturing the solid electrolytic capacitor is simplified, reliability is improved, and a withstand voltage of the solid electrolytic capacitor is increased. An anode element including a metal and a coating layer formed on a surface thereof, the coating layer being composed of a hydrated oxide shown as MOx.yH2O in chemical formula (1), where M represents a valve metal and x and y represent an integer or a decimal fraction from 1 to 6, a hydroxide shown as M(OH)n in chemical formula (2), where M represents a valve metal and n represents an integer or a decimal fraction from 1 to 6, or a composite thereof, a method of manufacturing the anode element, and a solid electrolytic capacitor employing the anode element are provided.