Solid Electrolyte Capacitor Process for Humidity-Stable ESR
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Solution Overview
Problem
Electrolytic capacitors experience significant fluctuations in equivalent series resistance (ESR) in high-humidity environments due to moisture ingress, leading to a decrease in conductivity and pH, particularly at elevated temperatures.
Innovation Solution
A method for manufacturing electrolytic capacitors involves forming a solid electrolyte by bringing a treatment liquid containing a conjugated polymer and a polymer dopant into contact with the anode body, followed by an aqueous solution generating organic anions and divalent metal ions, which trap eluted dopants to stabilize the pH and reduce ESR fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional solid electrolyte is used in high-humidity environments, then the capacitor can operate, but the ESR fluctuates significantly due to moisture ingress and dopant elution
Solution Approach 1:
The patent introduces an inorganic salt as an intermediary substance within the solid electrolyte composition. This salt acts as a mediator that interacts with eluted dopants and moisture, forming stable complexes that prevent pH degradation and maintain ESR stability in high-humidity environments
Solution Approach 2:
The patent creates a composite solid electrolyte material combining organic conjugated polymer, polymer dopant, and inorganic salt. This composite structure leverages the conductive properties of the polymer while the inorganic salt component provides stability against moisture and dopant elution effects
2Reliability
If the solid electrolyte is exposed to high humidity and temperature, then the capacitor operates, but the conductivity decreases due to pH decrease from dopant elution
Solution Approach 1:
The inorganic salt serves as a chemical intermediary that captures eluted dopants through complexation reactions. This intermediary mechanism prevents free dopant migration and the associated pH decrease that would otherwise occur in high-temperature high-humidity conditions
Solution Approach 2:
The patent modifies the chemical composition parameters of the solid electrolyte by adding inorganic salt components. This parameter change alters the chemical environment within the electrolyte, creating conditions that suppress dopant elution and maintain stable pH and conductivity
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
The method effectively suppresses ESR fluctuations and maintains conductivity by trapping dopants with divalent metal ions, even in high-humidity and high-temperature conditions, enhancing capacitor performance.
Implementation Method 1
bring an aqueous solution containing a compound that generates an organic anion and a divalent metal ion into contact with the anode body
Implementation Method 2
the divalent metal ion not including a divalent transition metal ion... trapping dopants with divalent metal ions
Implementation Method 3
The solid electrolyte is formed on the dielectric layer by in-situ polymerization such as chemical polymerization... bringing a treatment liquid containing a conjugated polymer and a polymer dopant into contact with the anode body
Data Source
AI summary
A method for manufacturing an electrolytic capacitor includes the steps of: preparing an anode body that includes a dielectric layer provided on a surface of the anode body; and forming a solid electrolyte. The step of forming the solid electrolyte includes substep A of bringing a treatment liquid containing a conjugated polymer and a polymer dopant into contact with the anode body, and at least one of (i) or (ii) below. (i) Substep B is further performed after the substep A to bring an aqueous solution containing a compound that generates an organic anion and a divalent metal ion (excluding a transition metal ion) into contact with the anode body. (ii) Substep C is further performed before the substep A to prepare the treatment liquid by mixing the aqueous solution containing the compound with a liquid composition containing the conjugated polymer and the polymer dopant.