Polymer Solid Electrolytic Capacitor to Prevent Electrolyte Evaporation
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Solution Overview
Problem
Known solid electrolytic capacitors deteriorate due to electrolyte evaporation when exposed to heat and vibration, leading to unstable capacitor characteristics over time.
Innovation Solution
A solid electrolytic capacitor design featuring a case with a water-soluble first polymer and a water-dispersible second polymer, along with a solid-at-normal-temperature substance that melts at a higher temperature, providing a stable electrolyte solution between the anode and cathode, and between the capacitor element and the case, which maintains capacitor characteristics and prevents electrolyte evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a liquid electrolyte is used in the capacitor element, then electrical conductivity is improved, but the electrolyte evaporates through the sealing member over time causing deterioration in capacitor characteristics
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid by using a solid-at-normal-temperature substance as the solvent. This fundamental parameter change eliminates evaporation while maintaining ionic conductivity through the solid matrix, directly resolving the contradiction between reliability and substance loss.
Solution Approach 2:
The patent creates a composite electrolyte system combining a solid-at-normal-temperature substance (solvent) with dissolved electrolytes and added polymers. This composite structure provides both the mechanical stability of a solid and the ionic conductivity of a liquid electrolyte, preventing evaporation while maintaining electrical performance.
2Reliability
If a solid-at-normal-temperature substance is used as electrolyte, then electrolyte evaporation is prevented, but the electrolyte must be heated to melt it which increases energy consumption
Solution Approach 1:
The patent utilizes phase transition of the solid-at-normal-temperature substance as a controlled mechanism. The substance remains solid at operating temperatures, transitioning to liquid only during deliberate heating cycles for oxide film repair, thereby maintaining stability during normal operation while enabling periodic regeneration.
Solution Approach 2:
The solid-at-normal-temperature substance serves dual functions: it provides stable electrolyte performance at room temperature and automatically repairs oxide films when heated, eliminating the need for separate maintenance operations and reducing overall energy consumption over the capacitor's lifetime.
3Reliability
If polymers are added to maintain low ESR, then electrical conductivity is improved, but the structure becomes more complex
Solution Approach 1:
The patent applies different polymer types in specific locations and concentrations within the electrolyte composition. Water-soluble polymers are used at controlled concentrations to provide ionic conductivity, while water-dispersible polymers are applied to electrode surfaces to enhance contact and reduce ESR, optimizing performance without excessive complexity.
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 ensures stable capacitor characteristics over a long period by preventing electrolyte evaporation and enhancing mechanical stability against external forces, while the solid-at-normal-temperature substance repairs oxide films and maintains low equivalent series resistance (ESR).
Implementation Method 1
a solid-at-normal-temperature substance is disposed that has an electrolyte dissolved in a solvent that is solid at or below a first temperature and that melts when heated to or above a second temperature higher than the first temperature
Implementation Method 2
a water-soluble first polymer disposed between the surface of the anode member and the surface of the cathode member; and a water-dispersible second polymer disposed on the surface of the anode member on which the first polymer is disposed and on the surface of the cathode member on which the first polymer is disposed. The second polymer electrically connects together the surface of the anode member and the surface of the cathode member
Data Source
AI summary
A capacitor element has a water-soluble first polymer disposed on the surfaces of anode and cathode members and a water-dispersible second polymer disposed on the surfaces of the anode and cathode members on which the first polymer is disposed. The second polymer electrically connects together the anode and cathode members. Between the surfaces of the anode and cathode members and between the inner face of a case and the outer face of the capacitor element, a solid-at-normal-temperature substance is disposed that has an electrolyte dissolved in a solvent that is solid at or below a first temperature and that melts when heated to or above a second temperature higher than the first temperature.