Solid Electrolyte Capacitor Layer Structure to Prevent Peeling
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Solution Overview
Problem
Existing solid electrolytic capacitors face issues with decreased electrostatic capacity and increased equivalent series resistance (ESR) due to peeling between multiple layers caused by expansion and contraction during charge and discharge cycles, particularly when multiple layers of conductive polymers are used.
Innovation Solution
The solid electrolytic capacitor design includes a first layer disposed in the voids of a porous anode body and an outer layer on the main surface, with a thickness of at least 1 μm, formed by applying a treatment liquid to vertically oriented main surfaces, enhancing adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple layers of conductive polymer are used in the solid electrolyte layer, then the electrostatic capacity is improved, but peeling between layers occurs during charge and discharge cycles causing decrease in electrostatic capacity and increase in ESR
Solution Approach 1:
The patent utilizes a porous anode body structure where the conductive polymer layers are formed within the porous framework. The porous structure provides mechanical interlocking between layers and the substrate, preventing peeling during charge-discharge cycles while maintaining high electrostatic capacity through increased surface area for polymer deposition.
Solution Approach 2:
The patent employs composite material structure by forming multiple layers of conductive polymer with different compositions or properties within the same solid electrolyte layer. This composite approach allows optimization of adhesion between layers while maintaining overall electrostatic capacity, as each layer can be tailored for specific functions such as bonding strength or charge storage.
2Reliability
If the outer layer thickness is increased to improve adhesion, then peeling is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the conductive polymer layers in a specific sequence during the manufacturing process, ensuring proper adhesion from the beginning. The outer layer is formed with sufficient thickness (≥1 μm) during the initial deposition process rather than requiring subsequent corrective steps, preventing peeling issues before they occur.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thickness of the outer layer to be at least 1 μm, which is a specific parameter threshold that ensures adequate adhesion. This quantitative parameter control provides a clear manufacturing specification that balances adhesion performance with process simplicity, avoiding overly complex manufacturing procedures.
3Reliability
If the treatment liquid is applied to vertically oriented main surfaces, then the outer layer thickness is uniformly increased to reduce peeling, but the manufacturing time increases
Solution Approach 1:
The patent applies treatment liquid to vertically oriented main surfaces of the porous anode body, utilizing a vertical/dimensional approach rather than horizontal application. This dimensional change allows the treatment liquid to penetrate and form a uniform outer layer thickness more efficiently, improving adhesion while minimizing the time required for liquid application and drying.
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 design improves adhesion between layers, reducing peeling and maintaining capacitor performance by minimizing decreases in electrostatic capacity and ESR, even under repeated use and high temperatures.
Implementation Method 1
drying the treatment liquid
Data Source
AI summary
A solid electrolytic capacitor includes at least one solid electrolytic capacitor element that includes an anode body having a sheet shape and including a porous part in a surface layer of the anode body, a dielectric layer covering at least a part of the porous part, and a cathode part. The cathode part includes a solid electrolyte layer covering at least a part of the dielectric layer. The solid electrolyte layer includes a first layer covering the at least the part of the dielectric layer, and a second layer covering at least a part of the first layer. The first layer includes an inner layer disposed in voids of the porous part, and an outer layer disposed outside a main surface of the porous part. A thickness Tm of the outer layer disposed outside the main surface is more than or equal to 1 μm.