Polymer Capacitor Electrolyte Process for Stable Capacitance and Low ESR
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Capacitors with solid electrolyte layers based on PEDOT/PSS experience significant deterioration in electrical properties over time, especially due to switch-on and switch-off processes in electronic circuits, leading to unstable capacitance and high equivalent series resistance.
Innovation Solution
A process for manufacturing capacitors involving the use of porous electrode bodies with a dielectric layer, where a conductive polymer dispersion with controlled conductivity is introduced, followed by partial removal of the dispersing agent and impregnation with a high-boiling solvent, resulting in a stable solid electrolyte layer that minimizes capacitance changes over time and across temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PEDOT/PSS dispersion is applied to the oxide layer and dispersing agent is removed by evaporation, then solid electrolyte layer is formed, but electrical properties deteriorate over time due to switch-on and switch-off processes
Solution Approach 1:
The patent changes the physical and chemical parameters of the solid electrolyte layer by incorporating high-boiling solvents (boiling point ≥150°C) such as diethylene glycol, triethylene glycol, or tetraethylene glycol into the PEDOT/PSS matrix. This parameter change modifies the layer's stability characteristics, preventing the deterioration that normally occurs during switch-on and switch-off cycles. The high-boiling solvent acts as a stabilizing agent that maintains the electrical properties throughout the capacitor's service life.
2Reliability
If conductive polymer dispersion with high conductivity is used, then low equivalent series resistance is achieved, but capacitance becomes unstable over time
Solution Approach 1:
The patent creates a composite solid electrolyte layer by combining conductive polymer particles (PEDOT/PSS) with high-boiling solvents. This composite structure integrates the low resistance properties of the conductive polymer with the stability properties of the high-boiling solvent. The conductive polymer provides the necessary electrical conductivity while the high-boiling solvent matrix ensures long-term capacitance stability, achieving both low equivalent series resistance and stable capacitance over time.
3Ease of manufacture
If dispersing agent is completely removed by evaporation, then solid electrolyte structure is formed, but manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent introduces high-boiling solvents as intermediary substances that remain in the solid electrolyte layer after the dispersing agent is removed. These intermediaries (diethylene glycol, triethylene glycol, or tetraethylene glycol) facilitate the formation of a stable solid electrolyte structure without requiring complete removal of the dispersing agent. This approach simplifies the manufacturing process while ensuring high-quality solid electrolyte layer formation, as the high-boiling solvents stabilize the layer during and after the drying process.
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 process ensures capacitors with stable electrical properties, low equivalent series resistance, and minimal capacitance change over long periods and varying temperatures, enhancing their reliability and performance in electronic circuits.
Implementation Method 1
introduction of a liquid composition A, preferably a dispersion A, which comprises an electrically conductive polymer and a dispersing agent
Implementation Method 2
at least partial removal of the dispersing agent from the porous electrode body obtained in process step b)
Implementation Method 3
filling at least a part of the pores of the porous electrode body obtained in process step c) with an impregnation solution comprising at least one impregnation solvent
Data Source
AI summary
A process for manufacturing a capacitor, comprising the process steps: a) provision of a porous electrode body made of an electrode material; b) introduction of a liquid composition which comprises an electrically conductive polymer and a dispersing agent into at least a part of the porous electrode body provided in process step a); c) at least partial removal of the dispersing agent from the porous electrode body obtained in process step b) for the formation of a solid electrolyte layer that at least partially covers a surface of the dielectric; d) filling at least a part of the pores of the porous electrode body obtained in process step c) with an impregnation solution comprising at least one impregnation solvent; e) at least partial removal of the impregnation solvent from the porous electrode body obtained in process step d); f) encapsulation of the porous electrode body obtained in process step e).