Solid Electrolytic Capacitor Electrolyte Layers for Higher Capacitance
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Solution Overview
Problem
Solid electrolytic capacitors have limitations in withstand voltage and capacitance relative to their size, restricting their application in various fields.
Innovation Solution
A solid electrolytic capacitor design featuring a porous sintered body anode, a dielectric layer, a multi-layered solid electrolyte layer with conductive polymers and electrolyte solutions, and a conductor cathode layer, optimized through specific treatment processes to enhance voltage resistance and capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solid electrolytic capacitor structure is used, then manufacturing is simple, but withstand voltage is limited and capacitance per unit size is small
Solution Approach 1:
The solid electrolyte layer is divided into multiple sub-layers (first solid electrolyte layer, second solid electrolyte layer, third solid electrolyte layer) with different functions. The first layer provides basic electrolytic function, the second layer with conductive polymer enhances capacitance, and the third layer with electrolyte solution improves wetting and reduces ESR. This segmentation allows each layer to be optimized independently for specific performance parameters.
Solution Approach 2:
The patent employs composite material structures in the solid electrolyte layer, combining different electrolyte materials (conductive polymers, electrolyte solutions) with the porous sintered body and dielectric layer. This composite approach enables the capacitor to achieve both high withstand voltage and high capacitance by leveraging the complementary properties of different materials.
2Quantity of substance
If capacitor size is reduced, then miniaturization is achieved, but capacitance decreases
Solution Approach 1:
The patent utilizes a porous sintered body structure as the anode, which provides a large internal surface area within a compact volume. The porous structure allows the dielectric layer and solid electrolyte layers to form extensive contact surfaces, significantly increasing the effective capacitance area without proportionally increasing the external dimensions of the capacitor.
Solution Approach 2:
The invention transitions from a simple planar electrode structure to a multi-dimensional porous sintered body structure with extensive internal surfaces. This dimensional transformation allows the capacitor to achieve high capacitance through the three-dimensional surface area of the porous anode, enabling compact size while maintaining or increasing capacitance.
3Loss of energy
If equivalent series resistance is reduced, then power loss decreases, but manufacturing complexity increases
Solution Approach 1:
The third solid electrolyte layer containing electrolyte solution acts as an intermediary between the second solid electrolyte layer and the external environment. This intermediary layer improves the wetting properties and ionic conductivity at the interface, effectively reducing equivalent series resistance and power loss while maintaining a manageable manufacturing process through sequential layer formation.
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 design improves withstand voltage and increases capacitance, reducing equivalent series resistance and enabling larger capacitance per unit size, thus expanding application possibilities.
Implementation Method 1
The solid electrolyte layer includes a first layer formed on the dielectric layer, and the first layer includes an electrolyte solution
Data Source
AI summary
This solid electrolytic capacitor is provided with: a porous sintered body that constitutes a positive electrode; a dielectric layer that is formed on the porous sintered body; a solid electrolyte layer that is formed on the dielectric layer; and a conductor layer that is formed on the solid electrolyte layer so as to constitute a negative electrode. The solid electrolyte layer comprises a first layer that is formed on the dielectric layer. The first layer contains an electrolyte solution. The electrolyte solution is composed, for example, of at least one substance that is selected from the group consisting of ethylene glycol, dimethylformamide, γ-butyrolactone, a polyalkylene glycol, a polyalkylene triol, and derivatives of these compounds. Alternatively, the electrolyte solution is composed of a polymer-based electrolyte solution or a carbonate-based electrolyte solution.