Conductive Polymer Electrolyte Filling for Porous Capacitor Electrodes
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Solution Overview
Problem
Existing methods for manufacturing conductive polymer solid electrolytic capacitors fail to sufficiently fill the porous material, resulting in insufficient capacitance appearance rates.
Innovation Solution
A method involving the impregnation of a porous material with a dispersion of conductive polymer in a non-aqueous solvent, where the conductive polymer includes specific structural units and a dopant, followed by solvent removal to form a solid electrolyte that effectively fills the pores, enhancing capacitance appearance rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conductive polymer is used to fill porous material in a capacitor, then the electrode capacitance can be improved, but the capacitance appearance rate becomes insufficient due to inadequate pore filling
Solution Approach 1:
The patent changes the solvent parameter from aqueous to non-aqueous (specifically using γ-butyrolactone), which fundamentally alters the conductive polymer's properties. This parameter change enables the polymer to adequately fill the porous material while achieving the target capacitance appearance rate of 90% or higher, resolving the contradiction between quantity of substance and manufacturing precision.
2Volume of moving object
If a conductive polymer dispersion is impregnated into porous material, then the porous structure can be filled, but the filling is insufficient when using aqueous solvents
Solution Approach 1:
The patent applies parameter change by switching from aqueous to non-aqueous solvent (γ-butyrolactone), which transforms the conductive polymer from a state that cannot sufficiently fill pores to one that achieves complete pore filling. This results in reliable capacitance appearance rates of 90% or higher while maintaining adequate polymer volume in the porous structure.
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 method achieves a high capacitance appearance rate by ensuring the pores of the porous material are adequately filled with the conductive polymer, thereby improving the electrode capacitance of the solid electrolytic capacitor.
Implementation Method 1
the conductive polymer introduction step comprises impregnating a porous material with a dispersion
Implementation Method 2
a solvent removal step, wherein: the conductive polymer introduction step comprises impregnating a porous material with a dispersion
Data Source
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AI summary
A method for manufacturing a conductive polymer solid electrolytic capacitor comprising a conductive polymer introduction step and a solvent removal step. The conductive polymer introduction step comprises impregnating a porous material with a dispersion. The dispersion includes a conductive polymer dispersed in a non-aqueous solvent and the conductive polymer includes at least one of the structural units represented by the following formula (1) and the following formula (2). In the formulas (1) and (2), R1 is an alkyl group having 1 to 12 carbon atoms, an alkoxy group having 1 to 12 carbon atoms, an alkylene oxide group having 1 to 12 carbon atoms and having 1 to 50 repeating units, a phenyl group optionally having a substituent, a heterocyclic group optionally having a substituent, or a condensed ring group optionally having a substituent, A- is an anion derived from a dopant and n is 2 or more and 300 or less. The porous material includes an electrode material which is a sintered body of particles, and a dielectric covering a surface of the electrode material. The solvent removal step comprises removing at least a part of the non-aqueous solvent and forming a solid electrolyte which covers the surface of the porous material.