Protective Layer Structure for Solid Electrolytic Capacitors

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The solid electrolyte layer in conventional solid electrolytic capacitors is prone to damage during the bonding process of the anode wire or during use.

Innovation Solution

A solid electrolytic capacitor design that includes a protective layer covering at least a portion of the first surface, with a first layer and a second layer formed on the dielectric layer, and a cathode layer on the second layer, using insulative materials like fluoropolymers to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the anode wire is bonded to the anode terminal, then electrical connection is established, but the solid electrolyte layer may be damaged during the bonding process

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddamage to solid electrolyte layer

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention applies a protective layer on the first surface of the porous sintered body before the bonding process. This protective layer acts as a cushioning barrier that prevents damage to the solid electrolyte layer during subsequent bonding operations, while allowing the anode wire to be properly bonded to the anode terminal.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The protective layer serves as an intermediary element between the bonding process and the solid electrolyte layer. It mediates the interaction by providing a protective interface that allows the bonding to proceed without directly exposing the vulnerable solid electrolyte layer to mechanical stress.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a protective layer is added to protect the solid electrolyte layer, then damage suppression is improved, but device complexity increases

Engineering Contradiction:

Improvesolid electrolyte layer protectionVSAvoidcapacitor structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective layer is implemented as a thin film coating on the first surface of the porous sintered body. This approach provides effective protection against damage while minimizing the increase in device complexity and overall capacitor size, as thin films add minimal bulk but significant protective function.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20240404761A1Solid Electrolytic Capacitor and Method for Producing Solid Electrolytic Capacitor

Publication Date: 2024.12.05 KYOCERA AVX COMPONENTS CORP

AI summary

The present invention provides: a solid electrolytic capacitor which is capable of suppressing damage on a solid electrolyte layer and a method for producing a solid electrolytic capacitor. This solid electrolytic capacitor is provided with: a porous sintered body 1 which has a first surface 11, while containing a valve-acting metal; a positive electrode wire 10 which protrudes from the first surface 11, while containing a valve-acting metal; a dielectric layer 2 which is formed on the porous sintered body 1; a solid electrolyte layer 3 which is formed on the dielectric layer 2; and a negative electrode layer 4 which is formed on the solid electrolyte layer 3. The solid electrolyte layer 3 comprises a first layer 31 which is formed on the dielectric layer 2 and a second layer 32 which is formed on the first layer 31; and this solid electrolyte capacitor comprises a protective layer 5 which covers at least a part of the first surface 11, with the first layer 31 being interposed therebetween.