High-Voltage Solid Electrolyte Capacitor Manufacturing via Water Dispersion Impregnation
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Solution Overview
Problem
Current solid electrolytic capacitors face limitations in achieving high voltage due to oxidant damage to the positive electrode foil and high leakage current, primarily because of the manufacturing process using solvents that impair the oxide film and result in low withstand voltage and poor batch consistency, especially for larger sizes.
Innovation Solution
A method involving the polymerization of conductive polymers in water to form a water dispersion, which is then used to impregnate the capacitor core under varying pressure conditions, ensuring even distribution and higher withstand voltage, and repeated impregnation steps with heat treatment to remove solvents and enhance absorption, resulting in a high-voltage solid electrolyte aluminum-electrolytic capacitor with lower ESR and improved consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monomers and oxidants are dissolved by using a solvent and enter a capacitor core by means of impregnating, then the conductive solid electrolyte is generated through polymerization, but the oxidant damages the oxidation film of the positive electrode foil, significantly reducing the original voltage value
Solution Approach 1:
The patent introduces a water-soluble polymer as an intermediary carrier that delivers monomers to the capacitor core without using traditional organic solvents. The polymer acts as a protective medium that prevents oxidant contact with the oxidation film while still enabling conductive electrolyte formation through controlled polymerization within the porous structure
Solution Approach 2:
The patent changes the solvent parameter from organic solvents to water, fundamentally altering the impregnation process. This parameter change eliminates the harmful effects of organic solvents on the oxidation film while maintaining the ability to deliver monomers and form conductive polymers through water-based polymerization
2Quantity of substance
If monomers and oxidant are dissolved in the solvent and infiltrate the capacitor core, then the capacitor core is well impregnated, but the oxidant and monomers are brought into etched pores of the anodized foil, resulting in low withstand voltage and high leakage current
Solution Approach 1:
The patent performs preliminary polymerization of monomers into water-soluble polymers before impregnation. This preliminary action ensures that the polymer chains are pre-formed and can be uniformly distributed throughout the capacitor core through water-based impregnation, filling pores and creating a continuous conductive network that reinforces the oxidation film and blocks leakage paths
Solution Approach 2:
The water-soluble polymer serves as an intermediary that fills the etched pores and provides structural support. The polymer network acts as a protective barrier within the pores, preventing direct contact between any remaining oxidant and the oxidation film, thereby maintaining high withstand voltage while achieving thorough impregnation
3Ease of manufacture
If ordinary impregnation manner is applied without considering the low impregnation effect of water, then the process is simple, but the capacitance withdrawing rate is low and product consistency is poor, especially for larger sizes
Solution Approach 1:
The patent applies dynamic pressure control during the water-based impregnation process. By dynamically adjusting the pressure parameters, the system overcomes the naturally low impregnation effect of water and ensures uniform distribution of the water-soluble polymer throughout the capacitor core, achieving both simple processing and high product consistency across different sizes
Solution Approach 2:
The patent employs periodic impregnation cycles with alternating pressure phases. This periodic action allows water to progressively penetrate the capacitor core structure in controlled stages, ensuring thorough and uniform impregnation of the water-soluble polymer while maintaining process simplicity and achieving consistent results for capacitors of various sizes
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 effectively increases the withstand voltage, reduces leakage current, and enhances capacitance withdrawal rate and batch consistency, particularly for larger capacitors, by generating a stable conductive polymer layer and optimizing the impregnation process.
Implementation Method 1
impregnating the capacitor core under different pressure conditions
Implementation Method 2
impregnating the capacitor core under different pressure conditions
Implementation Method 3
heat treatment to remove solvents
Implementation Method 4
polymerization of conductive polymers in water to form a water dispersion
Data Source
AI summary
A method for manufacturing a solid electrolyte aluminum-electrolytic capacitor, includes: (1) welding a capacitor core of a capacitor onto an iron bar, applying a voltage for chemical treatment, and thereafter, washing and drying the capacitor core; (2) impregnating the dried capacitor core in a dispersion B for 1˜30 minutes; (3) removing the capacitor core, creating a vacuum and then impregnating the capacitor core in the dispersion B for 1˜10 minutes; (4) while in the dispersion B, breaking the vacuum and performing pressurization for 1˜10 minutes; (5) while in the dispersion B, performing depressurization to atmospheric pressure, for 1˜10 minutes; (6) placing the capacitor core in a temperature of 50˜100° C. and drying for 20˜60 minutes, and then in a temperature of 110˜200° C. and drying for 20˜60 minutes; (7) impregnating the dried capacitor core in a dispersion C for 1˜30 minutes; (8) placing the capacitor core in a temperature of 65˜100° C. and drying for 20˜60 minutes, and then in a temperature of 135˜165° C. and drying for 20˜60 minutes; and (9) Repeating steps (3) to (8) at least once.