Polymer Solid Electrolytic Capacitor for Capacitance and Withstand Voltage
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Solution Overview
Problem
Existing solid electrolytic capacitors face challenges in achieving high capacitance and withstand voltage simultaneously due to issues with adhesiveness and void filling in the porous anode body, leading to capacitance drop and low breakdown voltage.
Innovation Solution
A solid electrolytic capacitor design with a dielectric layer thickness of 2.50 times the rated voltage, using electrolytic polymerization to form a solid electrolyte layer with a high packing density of conjugated polymer and polymer anion, ensuring uniform distribution and high conductivity, and employing three-pole electrolytic polymerization to control polymerization potential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid dispersion is used to form solid electrolyte, then formation process is simplified, but adhesiveness to porous anode body is poor and void filling is insufficient
Solution Approach 1:
The patent changes the chemical parameters of the dispersion solution by adjusting pH to match the porous anode body, and controls polymerization potential during electrolytic polymerization to enable the solid electrolyte to fully fill voids and adhere properly to the anode body, resolving the contradiction between ease of manufacture and reliability
Solution Approach 2:
The patent replaces simple liquid dispersion impregnation with electrolytic polymerization process, where electrical fields drive monomer penetration and polymer formation within the porous structure, achieving superior void filling and adhesion while maintaining processability
2Strength
If dielectric layer thickness is increased to improve withstand voltage, then breakdown voltage increases, but capacitance decreases
Solution Approach 1:
The patent optimizes the dielectric layer thickness to a specific range (50-200 nm) that balances breakdown voltage and capacitance, and adjusts the solid electrolyte composition to achieve high packing density, enabling simultaneous improvement of both withstand voltage and capacitance
3Reliability
If solid electrolyte packing density is increased to improve conductivity, then charging and discharging characteristics improve, but formation complexity increases
Solution Approach 1:
The patent uses electrolytic polymerization with controlled potential to achieve high packing density of solid electrolyte in the porous anode body. The electrical field drives monomer penetration and polymer formation, achieving superior conductivity and charging/discharging characteristics while maintaining a relatively simple one-step formation 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 design achieves high capacitance and withstand voltage, maintaining excellent charging and discharging characteristics while suppressing capacitance decrease and breakdown, even under repeated charging and discharging.
Implementation Method 1
solid electrolyte is often formed using a method that uses a liquid dispersion that contains a conjugated polymer and a dopant
Implementation Method 2
a dielectric layer covering at least a part of the anode foil
Data Source
AI summary
The solid electrolytic capacitor includes at least one capacitor element. The at least one capacitor element includes an anode foil including a porous part at least in a surface layer of the anode foil, a dielectric layer covering at least a part of the anode foil, and a solid electrolyte layer covering at least a part of the dielectric layer. The solid electrolyte layer contains a first polymer component containing a conjugated polymer, and a second polymer component containing a polymer anion. In a Raman spectrum of a surface layer of the solid electrolyte layer, a peak that is characteristic to the first polymer component is observed. An average thickness T (nm) of the dielectric layer is more than or equal to 2.5×Rv, where Rv (V) represents a rated voltage of the solid electrolytic capacitor.