Solid Electrolyte Capacitor Polymer Film Uniformity
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Solution Overview
Problem
The challenge in producing solid electrolyte capacitors is the difficulty in achieving uniform thickness of conductive polymer layers, leading to current leakage and limited capacity, as well as increased equivalent series resistance due to uneven layer formation during the chemical oxidative polymerization process.
Innovation Solution
A method involving the use of a polymerizable monomer solution containing a thiophene skeletal structure compound, with a dimer or trimer, applied onto a substrate, where the solution exhibits light absorbance in the range of 300-340 nm, enhancing polymerization rate and resulting in a uniform, dense polymer film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chemical oxidative polymerization is used to form conductive polymer layers, then the polymerization reaction proceeds quickly and large amounts of polymer can be formed, but the polymer film formation is difficult to control resulting in uneven thickness
Solution Approach 1:
The polymerization process is divided into multiple sequential steps: first applying a polymerizable monomer solution containing thiophene compound, then applying an oxidizing agent solution separately. This segmentation allows independent control of monomer deposition and polymerization reaction, preventing uncontrolled rapid polymerization that causes uneven thickness while maintaining high productivity through efficient reaction conditions.
Solution Approach 2:
The polymerizable monomer solution is applied to the substrate surface before the oxidizing agent is introduced. This preliminary action ensures uniform monomer distribution and adsorption on the substrate, creating a controlled starting layer that will polymerize uniformly when the oxidizing agent is subsequently applied, thus achieving both speed and uniformity.
2Reliability
If the polymer film thickness is increased to suppress current leakage, then leakage current is reduced, but the capacitor element thickness increases limiting further capacity enhancement
Solution Approach 1:
The invention changes the chemical parameters of the polymerization system by using specific thiophene compound monomers with controlled electronic structures and selecting appropriate oxidizing agents with optimal oxidation potentials. This parameter optimization enables the formation of highly uniform polymer films with sufficient thickness for leakage suppression while minimizing overall element thickness through efficient space utilization.
Solution Approach 2:
The conductive polymer layer is formed as a composite structure involving the polymerizable monomer (thiophene compound), the oxidizing agent, and the substrate. This composite approach allows optimization of each component's properties to achieve uniform thin films with excellent electrical characteristics, suppressing leakage current without requiring excessive thickness.
3Length of moving object
If the polymer film is made thinner to reduce element thickness, then element thickness is reduced, but current leakage increases
Solution Approach 1:
By precisely controlling the concentration and chemical structure parameters of the thiophene compound monomer solution and the oxidizing agent, the invention achieves optimal polymerization that forms sufficiently dense and uniform thin films. These films maintain adequate thickness for leakage suppression while keeping overall element thickness minimal, resolving the trade-off between thinness and reliability.
4Productivity
If the polymerization reaction is accelerated to improve productivity, then production time is reduced, but the uniformity of polymer film formation deteriorates
Solution Approach 1:
The accelerated polymerization process is segmented into distinct phases: rapid monomer solution application followed by separate oxidizing agent application. This segmentation allows the reaction to proceed quickly once initiated while maintaining uniformity through the controlled sequence of operations, preventing the uniformity deterioration that would occur with uncontrolled rapid polymerization.
Solution Approach 2:
The polymerizable monomer solution acts as an intermediary between the substrate and the oxidizing agent. By first establishing a uniform monomer layer on the substrate, this intermediary ensures that when the oxidizing agent is subsequently applied, the polymerization reaction proceeds rapidly and uniformly throughout the layer, achieving both high productivity and film uniformity.
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 allows for the stable production of thin, uniform solid electrolyte capacitors with high capacity and reduced equivalent series resistance, minimizing short-circuiting and leakage current.
Implementation Method 1
a method for producing a solid electrolyte comprising the steps of: applying a solution containing a compound having a thiophene skeletal structure as a polymerizable monomer onto a substrate surface, and polymerizing the applied polymerizable monomer
Data Source
AI summary
A method for producing a solid electrolyte, which includes the steps of applying a solution containing a five-membered heterocyclic compound as a polymerizable monomer on a substrate surface, and polymerizing the applied monomer to give a solid electrolyte. The monomer-containing solution contains the polymerizable monomer and at least one polymerizable compound selected from a dimer of the monomer and a trimer of the monomer, at a proportion satisfying the equation:A/(B+C)=100-1,000,000whereA: concentration of the polymerizable monomer,B: concentration of the dimmer in terms of the concentration of its monomer, andC: concentration of the trimer in terms of the concentration of its monomer. In another aspect, a method is disclosed wherein a solution of a compound having a thiophene skeletal structure, which solution has a light absorbance of 1.5-10 at 300-340 nm, is applied on a substrate surface and polymerized.