Porous Sintered Anode Body with Density Gradient for Capacitor
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Solution Overview
Problem
Conventional solid electrolytic capacitors with porous sintered anode bodies face challenges in forming a sufficient solid electrolyte layer due to high density of valve metal particles, leading to poor impregnation and increased leakage current.
Innovation Solution
A solid electrolytic capacitor design featuring a porous sintered anode body with a hexahedral shape, where the anode lead is embedded in a region with a lower density third region, ensuring strong fixation and improved impregnation properties by adjusting the thickness and density gradients within the anode body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the density of valve metal particles is increased in the sintered body, then the strength and structural integrity of the anode body is improved, but the impregnation property with respect to raw material liquid for forming solid electrolyte layer deteriorates
Solution Approach 1:
The anode body is designed with non-uniform density distribution, where the third region has lower density than the first and second regions. This local quality variation allows the lower density region to provide good impregnation properties for solid electrolyte formation, while the higher density first and second regions provide structural strength and support.
2Stability of the object's composition
If the density of valve metal particles is increased in the sintered body, then the structural integrity is improved, but the formation of sufficient solid electrolyte layer becomes difficult
Solution Approach 1:
The anode body incorporates a third region with lower density specifically positioned to facilitate raw material liquid impregnation and solid electrolyte layer formation, while maintaining first and second regions with higher density for structural integrity. This local differentiation resolves the contradiction between structural stability and substance formation capability.
3Strength
If the anode lead is embedded in a high density region, then the fixation strength is improved, but the impregnation property of the surrounding area deteriorates
Solution Approach 1:
The anode lead is embedded in the third region which has lower density than the first and second regions. This lower density region provides excellent impregnation properties for raw material liquid while still maintaining adequate fixation strength for the anode lead, thus resolving the contradiction between fixation strength and surrounding area impregnation.
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
This configuration results in a capacitor with large capacitance and low leakage current, enhancing the impregnation of the solid electrolyte layer and securing the anode lead's fixation, thereby improving the overall performance.
Implementation Method 1
The porous sintered body is obtained by sintering particles of a valve metal such as tantalum, niobium, or titanium... the impregnation property of the sintered body deteriorates with respect to a raw material liquid for forming a solid electrolyte layer
Data Source
AI summary
A solid electrolytic capacitor includes a capacitor element having an anode body that is a porous sintered body having a hexahedral shape, an anode lead, a dielectric layer, and a solid electrolyte layer. One end of the anode lead is embedded into the anode body from a first surface of the anode body. The anode body includes a second surface and a third surface which are opposite to each other. The anode body has a first region including the second surface, a second region including the third surface, and a third region interposed between the first region and the second region. The third region has lower density than each of the first region and the second region. An average thickness T3 of the third region and a thickness TL of the anode lead satisfy a relationship T3<TL. A surface of the anode lead is in contact with at least one of the first region and the second region.