Solid Electrolytic Capacitor Layout for Low ESR and Leakage Control
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Solution Overview
Problem
Existing solid electrolytic capacitors face challenges in achieving low equivalent series resistance while minimizing leakage current defects.
Innovation Solution
The design includes a solid electrolytic capacitor element with a solid electrolyte layer covering part of the insulating mask layer, a carbon layer covering the same or closer to the negative electrode portion, and a negative conductor layer covering closer to the carbon layer, with a non-formed region where the negative conductor layer does not cover the carbon layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the solid electrolyte layer is formed to cover the insulator layer and the highly conductive paste layer is formed to cross the insulator boundary, then the equivalent series resistance is reduced, but the leakage current defect increases
Solution Approach 1:
The patent applies local quality by creating a negative conductor layer-non-formed region at specific locations where the negative conductor layer does not cover the carbon layer. This localized modification allows the structure to maintain low equivalent series resistance through the conductive layers while preventing leakage current defects by excluding the negative conductor layer from critical areas adjacent to the insulator layer, thus achieving spatially differentiated functionality.
2Loss of energy
If the negative conductor layer is formed to cover the carbon layer completely, then the electrical conductivity is improved, but the leakage current defect increases
Solution Approach 1:
The patent implements local quality by defining a negative conductor layer-non-formed region where the negative conductor layer is intentionally absent. This creates a spatial differentiation: areas with negative conductor layer provide high electrical conductivity, while the non-formed region prevents leakage current defects by maintaining insulation near the insulator layer boundary.
Solution Approach 2:
The patent segments the carbon layer coverage area into two functional zones: a region covered by the negative conductor layer for electrical conductivity, and a negative conductor layer-non-formed region for preventing leakage current. This segmentation allows simultaneous optimization of both conductivity and reliability.
Data Source
AI summary
A solid electrolytic capacitor element that includes: a valve acting metal substrate having a dielectric layer thereon; an insulating mask layer on the dielectric layer and separating the valve acting metal substrate into positive and negative electrode portions; a solid electrolyte layer on the dielectric layer, a tip of the solid electrolyte layer covering an outer surface of the insulating mask layer; a carbon layer on the solid electrolyte layer, a tip of the carbon layer covering a same position as the tip of the solid electrolyte layer or a position closer to the negative electrode portion; and a negative conductor layer on the carbon layer, a tip of the negative conductor layer covering a position closer to the negative electrode portion, and wherein the negative electrode portion has a negative conductor layer-non-formed region where the negative conductor layer does not cover a part of the carbon layer.