Polyaniline Solid Electrolyte Capacitor for Low Leakage and High Voltage
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Solution Overview
Problem
Conventional solid electrolytic capacitors using in situ polymerized polymers suffer from high leakage current and capacitance loss, especially at high voltages and in humid environments, necessitating an improvement in electrical stability.
Innovation Solution
A solid electrolytic capacitor design featuring a sintered porous anode body, a dielectric, a solid electrolyte, and an external polymer coating with conductive polymer particles, where the solid electrolyte includes conductive polymer units derived from an aniline monomer, enhancing breakdown voltage, surge current handling, and capacitance recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If in situ polymerized polymers are used as solid electrolyte, then low ESR is achieved, but high leakage current and capacitance loss occur
Solution Approach 1:
The patent employs a composite solid electrolyte system combining PEDOT:PSS dispersion with additional conductive polymer components. This composite approach maintains the low ESR特性 of PEDOT:PSS while adding stability and reducing leakage current through the synergistic effects of multiple polymer materials working together.
Solution Approach 2:
The patent modifies the chemical composition and physical parameters of the solid electrolyte by using specific dispersions and additives. By changing the electrolyte's chemical structure and properties, the patent achieves both low ESR and reduced leakage current, resolving the contradiction between these two parameters.
2Use of energy by moving object
If in situ polymerized polymers are used as solid electrolyte, then low ESR is achieved, but failure at high voltages occurs
Solution Approach 1:
The patent creates a composite electrolyte structure that combines PEDOT:PSS with other conductive polymer materials. This composite structure provides both the low ESR needed for performance and enhanced breakdown voltage resistance through the combined properties of different polymers.
Solution Approach 2:
The patent applies protective measures in advance by using a carefully formulated dispersion system with additives that prevent breakdown before it occurs. The electrolyte composition is designed to resist high voltage stress proactively, cushioning against potential failure modes.
3Ease of manufacture
If polymer slurry-based capacitors are used, then manufacturing is simplified, but low wet capacitance percentage is achieved
Solution Approach 1:
The patent optimizes the slurry composition parameters including polymer concentration, solvent type, and additive ratios. By carefully adjusting these parameters, the patent achieves high wet capacitance percentage while maintaining the simplicity of the slurry-based manufacturing process.
Solution Approach 2:
The patent uses pre-synthesized polymer dispersions as copies of the desired electrolyte structure, eliminating the need for complex in situ polymerization processes. This approach simplifies manufacturing while ensuring high capacitance through the use of optimized dispersion formulations.
4Ease of manufacture
If polymer slurry-based capacitors are used, then manufacturing is simplified, but large capacitance loss in humid atmosphere occurs
Solution Approach 1:
The patent formulates a composite slurry system combining PEDOT:PSS with hydrophobic polymer components and protective additives. This composite structure maintains manufacturing simplicity while providing resistance to humidity-induced capacitance loss through the synergistic effects of different materials.
Solution Approach 2:
The patent uses a slurry-based approach that allows for simple replacement and reapplication of the electrolyte layer. While individual components may have limited stability, the overall system maintains performance through easy maintenance and the use of cost-effective, stable polymer materials.
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 capacitor exhibits improved electrical properties such as high breakdown voltage, low leakage current, and minimal capacitance loss, maintaining stability under various conditions including high temperatures and humidity, with a capacitance recovery of 75% or more and low equivalent series resistance.
Implementation Method 1
an external polymer coating that overlies the solid electrolyte and includes conductive polymer particles
Implementation Method 2
the solid electrolyte includes a conductive polymer having repeating units derived from an aniline monomer
Data Source
AI summary
A solid electrolytic capacitor containing a capacitor element is provided. The capacitor element contains a sintered porous anode body, a dielectric that overlies the anode body, a solid electrolyte that overlies the dielectric, and an external polymer coating that overlies the solid electrolyte and includes conductive polymer particles. The solid electrolyte includes a conductive polymer having repeating units derived from an aniline monomer having the following general formula (I):