Conductive Polymer Dispersion for Low-ESR Solid Electrolytes
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Solution Overview
Problem
Conductive polymers form spongy aggregates during polymerization inside electrolytic capacitor elements, leading to poor uniformity and increased equivalent series resistance (ESR), and existing methods using aqueous dispersions of conductive polymers do not sufficiently reduce ESR in solid electrolytic capacitors.
Innovation Solution
A conductive polymer-containing dispersion is formulated with a cyclic ether compound having a specific structure, including a conjugated conductive polymer, a polyanion, and a hydroxyl group-containing cyclic ether compound, which is applied to a porous anode body to form a solid electrolyte layer, reducing ESR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive polymer is formed by polymerization inside the electrolytic capacitor element, then the solid electrolyte can be formed, but the conductive polymer forms spongy aggregates leading to poor uniformity and increased ESR
Solution Approach 1:
The conductive polymer is pre-formed as a fine-particle dispersion outside the capacitor element before being applied to the anode body. This preliminary preparation prevents spongy aggregate formation during polymerization inside the element, ensuring uniform distribution and low ESR in the final solid electrolyte layer.
Solution Approach 2:
The invention changes the physical state of the conductive polymer from bulk polymerized form to fine-particle dispersion form. By controlling particle size and distribution in the dispersion, the polymer can be uniformly applied to the anode body, preventing aggregate formation and reducing ESR while maintaining reliability.
2Object-generated harmful factors
If an aqueous dispersion of conductive polymer is used to form the solid electrolyte, then the ESR can be reduced, but the ESR is not sufficiently low compared to the target performance
Solution Approach 1:
The invention optimizes parameters of the aqueous dispersion including particle size distribution, polymer concentration, and dispersion stability. These parameter adjustments enable the dispersion to form a more uniform and conductive solid electrolyte layer, achieving sufficiently low ESR while maintaining high reliability and conductivity performance.
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 proposed dispersion significantly reduces the ESR of solid electrolytic capacitors, enhancing their performance by improving conductivity and uniformity of the solid electrolyte.
Implementation Method 1
performing oxidation polymerization or electrolysis polymerization inside the electrolytic capacitor element
Implementation Method 2
performing oxidation polymerization or electrolysis polymerization inside the electrolytic capacitor element
Implementation Method 3
A method of forming a solid electrolyte by permeating an aqueous dispersion of a conductive polymer into a dielectric oxide film for an anode body
Data Source
AI summary
Provided are a conductive polymer-containing dispersion which can further reduce the equivalent series resistance (ESR) of a solid electrolytic capacitor, a method of producing the same, and a solid electrolytic capacitor having a further reduced ESR. A conductive polymer-containing dispersion comprising a conjugated conductive polymer (A), a polyanion (B), a hydroxyl group-containing cyclic ether compound (C), and a dispersion medium (D).