Self-Doped Electrolyte Layer for High-Temperature ESR Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrolytic capacitors face a challenge in maintaining low equivalent series resistance (ESR) over a long period, particularly in high-temperature environments, due to dedoping of dopants in the electrolyte layer, which leads to increased ESR with time.
Innovation Solution
The use of a self-doped conductive polymer and a non-aqueous solvent in the electrolyte layer, combined with a polymer dopant containing an acidic group, helps to suppress the increase in ESR over time by minimizing dedoping, and the manufacturing method involves forming a polymer layer with these components adjacent to the dielectric layer and impregnating it with a non-aqueous solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a self-doped conductive polymer with non-aqueous solvent is used in the electrolyte layer, then ESR stability over time is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The self-doped conductive polymer is prepared in advance with dopant groups already incorporated into its structure during polymerization. This preliminary action of pre-doping eliminates the need for separate doping steps in the manufacturing process, reducing complexity despite the advanced material requirements. The polymer arrives ready-to-use as a self-doped material.
Solution Approach 2:
The self-doped conductive polymer inherently maintains its doping state without requiring external dopant supply or complex doping equipment. The material serves itself by containing the necessary dopant groups within its molecular structure, simplifying the manufacturing process while achieving superior ESR stability.
2Reliability
If conventional dopants are used in the conductive polymer, then the polymer achieves high conductivity, but the dopants dedope over time leading to increased ESR
Solution Approach 1:
The patent fundamentally changes the doping mechanism by incorporating dopant groups directly into the polymer backbone during synthesis. This parameter change from external doping to intrinsic self-doping ensures both high conductivity and stable dopant retention, as the dopant groups are covalently bonded and cannot dedope under normal operating conditions.
Solution Approach 2:
The self-doped conductive polymer creates an integrated composite where the polymer chain and dopant groups form a unified molecular structure. This composite approach ensures simultaneous achievement of high conductivity through the conjugated polymer backbone and stable dopant retention through covalent bonding, eliminating the trade-off between conductivity and stability.
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 approach results in an electrolytic capacitor with a low increase in ESR over a long period, even in high-temperature conditions, by preventing dedoping and maintaining conductivity, thus outperforming traditional solid electrolytic capacitors.
Implementation Method 1
The electrolyte layer contains a first conductive polymer and a non-aqueous solvent. The first conductive polymer is a self-doped conductive polymer.
Implementation Method 2
a step (ii) of forming a polymer layer containing a first conductive polymer to be adjacent to the dielectric layer by an impregnation treatment, and a step (iii) of impregnating the polymer layer with a non-aqueous solvent
Data Source
AI summary
An electrolytic capacitor includes a capacitor element. The capacitor element includes an anode body and an electrolyte layer. The anode body has a dielectric layer on a surface of the anode body. The electrolyte layer is disposed to be adjacent to the dielectric layer. The electrolyte layer contains a first conductive polymer and a non-aqueous solvent. The first conductive polymer is a self-doped conductive polymer.