Liquid Dispersion for Solid Electrolytic Capacitor Anode Coating
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Solution Overview
Problem
Existing methods for producing solid electrolytic capacitors face challenges in forming high-capacity solid electrolyte layers efficiently, particularly in achieving a high capacitance incidence ratio and effective frequency performance.
Innovation Solution
A liquid dispersion composition containing a conjugated conductive polymer and a condensed polycyclic compound monomer is applied to a porous anode body with a dielectric coating film, where the dispersion medium is removed to polymerize the monomer, forming a solid electrolyte layer with enhanced capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conductive polymer solution or suspension liquid is applied to a metal surface to form a solid electrolyte layer, then the capacitance incidence ratio is improved, but the production process becomes complex and productivity decreases
Solution Approach 1:
The invention changes the physical-chemical parameters of the dispersion medium by selecting specific solvents (water, alcohols, esters, ketones, nitriles, or their mixtures) and controlling the molecular weight and structure of the polyacrylonitrile polymer. This optimization allows the conductive polymer to be effectively dispersed and applied while maintaining high capacitance incidence ratio, thus improving manufacturing precision without sacrificing productivity.
2Manufacturing precision
If multiple coating steps are used to form solid electrolyte layers, then the capacitance incidence ratio is improved, but the number of process steps increases and manufacturing complexity rises
Solution Approach 1:
The invention combines the dispersion medium removal step with the polymerization step into a single integrated process. The dispersion medium is removed and the monomer is polymerized in one continuous operation, eliminating the need for separate coating and treatment steps. This merging of operations maintains high capacitance incidence ratio while significantly reducing production process complexity.
3Ease of operation
If the viscosity of the conductive polymer dispersion is reduced, then the ease of application is improved, but the polymerization control becomes more difficult
Solution Approach 1:
The invention optimizes the molecular weight of the polyacrylonitrile polymer within the range of 10,000 to 1,000,000 and adjusts the solvent composition to achieve the right balance between viscosity and polymerization control. This parameter optimization ensures the dispersion has sufficiently low viscosity for easy application while maintaining adequate viscosity for effective polymerization control and uniform layer formation.
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 method enables the production of solid electrolytic capacitors with improved capacitance incidence ratio and frequency performance, simplifying the production process while maintaining high reliability and heat resistance.
Implementation Method 1
the dispersion medium is removed and the condensed polycyclic compound monomer is polymerized to form a solid electrolyte layer
Data Source
AI summary
A liquid dispersion composition for solid electrolytic capacitor production, containing a conjugated conductive polymer prepared by polymerizing a monomer compound in a dispersion medium containing seed particles with protective colloid formed of a polyanion or in a dispersion medium containing a polyanion, and a compound (a) represented by a general formula (1), where R1 to R6 and k are as defined in the description; and a method for producing a solid electrolytic capacitor, including a step of adhering the composition to a porous anode body made of a valve action metal having a dielectric coating film on the surface thereof, and a step of removing the dispersion medium from the liquid dispersion composition having adhered to the porous anode body to form a solid electrolyte layer