Pre-Coated Conductive Polymer Capacitor for Low Leakage Stability
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Solution Overview
Problem
Conventional solid electrolytic capacitors with in situ polymerized polymers exhibit high leakage current and fail at high voltages, and those using PEDOT:PSS dispersions have poor electrical performance, particularly in terms of capacitance stability.
Innovation Solution
A solid electrolytic capacitor design featuring an anode body, a dielectric, a pre-coat formed from an organometallic compound, and a solid electrolyte with an intrinsically conductive polymer containing repeating thiophene units, which enhances breakdown voltage, dielectric strength, and capacitance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If in situ polymerized polymers are used as solid electrolyte, then low ESR is achieved, but leakage current increases and breakdown voltage decreases
Solution Approach 1:
A pre-coat layer is applied to the dielectric surface before applying the solid electrolyte. This pre-coat serves as a foundation that improves the interface between dielectric and electrolyte, enabling the use of intrinsically conductive polymers with low ESR while maintaining high breakdown voltage and low leakage current through enhanced interfacial properties
Solution Approach 2:
The solid electrolyte uses intrinsically conductive polymers (ICPs) with specific chemical structures containing repeating thiophene units, which inherently provide both low ESR and high electrical strength without requiring complex composite formulations, thus achieving reliable electrical performance
2Reliability
If PEDOT:PSS dispersions are used as solid electrolyte, then leakage current is reduced, but capacitance stability deteriorates
Solution Approach 1:
The patent specifies precise chemical parameters for the intrinsically conductive polymer, including repeating units with particular substituent groups (R = alkyl or halogen, M = hydrogen, alkali metal, or specific amine groups). These parameter specifications ensure both low leakage current and stable capacitance by controlling the polymer's electrical and chemical properties
Solution Approach 2:
The pre-coat layer provides localized improvement at the dielectric-electrolyte interface, creating optimal conditions for the solid electrolyte to achieve both low leakage current and high capacitance stability through enhanced interfacial adhesion and electrical contact
3Ease of manufacture
If conventional solid electrolyte structures are used, then manufacturing is simple, but electrical performance under high voltage and temperature conditions deteriorates
Solution Approach 1:
The pre-coat is applied as a preliminary step before the solid electrolyte, creating a prepared surface that enhances the final capacitor's electrical performance under high voltage and temperature conditions while maintaining a straightforward manufacturing process
Solution Approach 2:
The combination of dielectric, pre-coat, and intrinsically conductive polymer electrolyte creates a composite structure that delivers superior electrical performance under stress conditions while remaining compatible with conventional manufacturing techniques
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 capacitor achieves improved electrical properties, including high breakdown voltage, low leakage current, and stable capacitance under various conditions, including high temperatures and repeated surge voltage cycles.
Implementation Method 1
The solid electrolyte includes an intrinsically conductive polymer containing repeating thiophene units
Implementation Method 2
a pre-coat that overlies the dielectric and that is formed from an organometallic compound
Implementation Method 3
a dielectric that overlies the anode body
Data Source
AI summary
A solid electrolytic capacitor containing a capacitor element is provided. The capacitor element contains an anode body, a dielectric that overlies the anode body, a pre-coat that overlies the dielectric and that is formed from an organometallic compound, and a solid electrolyte that overlies the dielectric. The solid electrolyte includes an intrinsically conductive polymer containing repeating thiophene units of a certain formula.