Layered Conductive Polymer Electrolyte for Low-ESR Solid Capacitors
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Solution Overview
Problem
The insulation of dielectric layers in solid electrolytic capacitors deteriorates when conductive polymers are formed using chemical polymerization, leading to potential dielectric breakdown and increased equivalent series resistance (ESR).
Innovation Solution
A solid electrolytic capacitor design featuring a solid electrolyte layer composed of a first conductive polymer doped with a monomolecular dopant, a self-doped-type conductive polymer with side chains, and a third conductive polymer doped with a polymer dopant, where the first conductive polymer is in contact with the third conductive polymer, minimizing the amount of chemical polymerization and enhancing conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical polymerization is performed multiple times to form conductive polymer, then conductivity of solid electrolyte layer is improved, but insulation of dielectric layer deteriorates
Solution Approach 1:
The solid electrolyte layer is divided into multiple layers with different functions: a first layer containing conductive polymer formed by chemical polymerization (providing conductivity), and a second layer containing self-doped-type conductive polymer (minimizing dielectric damage). This segmentation allows each layer to optimize its contribution to conductivity while reducing overall harm to the dielectric layer insulation.
Solution Approach 2:
The invention uses composite material structure combining different types of conductive polymers (chemically polymerized and self-doped-type) in a layered configuration. This composite approach leverages the high conductivity of chemically polymerized polymer while using the gentler self-doped-type polymer to protect the dielectric layer, achieving both conductivity and insulation preservation.
2Object-affected harmful factors
If chemical polymerization is performed fewer times to preserve dielectric layer insulation, then insulation is maintained, but conductivity of solid electrolyte layer decreases
Solution Approach 1:
The self-doped-type conductive polymer acts as an intermediary layer between the dielectric layer and the chemically polymerized conductive polymer. It provides a protective interface that reduces direct damage to the dielectric layer while still enabling sufficient conductivity through the combined layered structure.
Solution Approach 2:
Different regions of the solid electrolyte layer are assigned different qualities: the first layer (in contact with dielectric) uses self-doped-type polymer for gentle conductivity, while the second layer uses chemically polymerized polymer for enhanced conductivity. This local differentiation optimizes both insulation protection and overall conductivity.
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 suppresses dielectric layer insulation deterioration and reduces ESR, preventing dielectric breakdown while maintaining conductivity, thus providing a stable and efficient solid electrolytic capacitor.
Implementation Method 1
a first layer containing a first conductive polymer doped with a monomolecular dopant
Implementation Method 2
a second layer formed on the first layer and containing a third conductive polymer doped with a polymer dopant
Implementation Method 3
a second conductive polymer composed of a self-doped-type conductive polymer containing a plurality of side chains containing a functional group, the functional group being able to be doped
Data Source
AI summary
A solid electrolytic capacitor according to an aspect includes an anode body made of a valve metal, a dielectric layer formed on the anode body, a solid electrolyte layer formed on the dielectric layer, and a cathode body layer formed on the solid electrolyte layer. The solid electrolyte layer includes a first layer containing a first conductive polymer doped with a monomolecular dopant, and a second conductive polymer composed of a self-doped-type conductive polymer containing a plurality of side chains containing a functional group, the functional group being able to be doped, and a second layer formed on the first layer and containing a third conductive polymer doped with a polymer dopant; and the first conductive polymer is in contact with the third conductive polymer (the second layer).