Solid Electrolytic Capacitor Morpholine Polymer Coating
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Solution Overview
Problem
Solid electrolytic capacitors face challenges in achieving high capacitance, heat resistance, and reliability under high-temperature conditions, particularly in applications like inverter power supplies and on-board units where temperature stability is crucial.
Innovation Solution
A method involving the use of a dispersion containing a morpholine compound and a conjugated conductive polymer is applied to a porous anode body with a dielectric film, forming a solid electrolyte layer through chemical oxidative polymerization, which enhances the capacitor's performance by improving heat resistance and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymerization methods are used to form solid electrolyte layers, then the manufacturing process is simple, but the heat resistance and high-temperature reliability are insufficient
Solution Approach 1:
The patent changes the chemical parameters of the polymerization process by introducing a morpholine compound as a catalyst and controlling the polymerization in a dispersion medium. This chemical parameter change enables the formation of a solid electrolyte layer with enhanced heat resistance and high-temperature reliability while maintaining process feasibility
Solution Approach 2:
The patent creates a composite solid electrolyte layer by combining conjugated conductive polymer with morpholine compound in a dispersion medium. This composite structure achieves superior heat resistance and high-temperature reliability that neither component could achieve alone, resolving the contradiction between improved reliability and process complexity
2Quantity of substance
If thicker solid electrolyte layers are formed to increase capacitance, then the capacity appearance ratio improves, but the manufacturing complexity and process control difficulty increase
Solution Approach 1:
The patent prepares a pre-formulated dispersion medium containing the conjugated conductive polymer, morpholine compound, and other components before application. This preliminary preparation ensures uniform distribution of components and enables precise control of layer thickness during the coating process, achieving high capacitance with controlled thickness
Solution Approach 2:
The patent controls the concentration and composition parameters of the dispersion medium to optimize the polymerization process. By adjusting these parameters, the method achieves uniform thick electrolyte layers with high capacitance while maintaining precise manufacturing control
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 method results in a solid electrolytic capacitor with a high capacity appearance ratio, excellent heat resistance, and high reliability under high-temperature conditions, making it suitable for demanding applications.
Implementation Method 1
forming a solid electrolyte layer through chemical oxidative polymerization
Implementation Method 2
A solid electrolytic capacitor is manufactured by forming a dielectric oxide film on the surface of a metal through anodization
Data Source
AI summary
A method of manufacturing a solid electrolytic capacitor, including: a step (A) of providing a conjugated conductive polymer-containing dispersion by polymerizing, in a dispersion medium containing seed particles turned into protective colloid by a polyanion or in a dispersion medium containing the polyanion, a monomer for obtaining a conjugated conductive polymer; a step (B) of preparing a dispersion containing a morpholine compound and the conjugated conductive polymer by adding the morpholine compound to the conjugated conductive polymer-containing dispersion; a step (C) of causing the dispersion to adhere to a porous anode body formed of a valve metal having a dielectric film on a surface thereof; and a step (D) of forming a solid electrolyte layer by removing the dispersion medium from the dispersion containing the morpholine compound and the conjugated conductive polymer, the dispersion adhering to the porous anode body.