Solid Electrolytic Capacitor Dual-Side Porous Structure
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Solution Overview
Problem
Conventional solid electrolytic capacitors have poor volume efficiency and a small capacitance-to-volume ratio due to their two-terminal design with lead frames, making it difficult to achieve the required capacitance and resulting in a bulky device.
Innovation Solution
A solid electrolytic capacitor design featuring a valve action metal base with porous portions on both surfaces, dielectric and solid electrolyte layers forming capacitance portions on both sides, and a connection portion that extends one capacitance portion to the surface, eliminating the need for external electrodes on the opposite surface, thereby increasing capacitance efficiency and allowing for a thinner design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-terminal design with lead frames is used, then the capacitor structure is simple and easy to manufacture, but the volume efficiency is poor and the capacitance-to-volume ratio is small
Solution Approach 1:
The patent transitions from a conventional single-sided capacitance structure to a dual-sided capacitance structure by forming porous portions, dielectric layers, and solid electrolyte layers on both surfaces of the valve action metal base. This dimensional expansion effectively doubles the capacitance generation area within the same volume, significantly improving volume efficiency while maintaining manufacturing simplicity
Solution Approach 2:
The capacitor is segmented into multiple functional regions: a core portion for structural support and a porous portion for capacitance generation on each surface. The valve action metal base is divided into regions with different functionalities (core vs. porous), allowing simultaneous optimization of mechanical strength and capacitance density, thereby improving overall volume efficiency
2Reliability
If external electrodes are provided on both surfaces, then electrical connection is achieved, but the device occupies more space and cannot be made thin
Solution Approach 1:
The patent merges the electrical connection function with the capacitance generation structure by forming the solid electrolyte layer to extend through the thickness direction, creating a through-electrode structure that provides both capacitance and electrical connection simultaneously. This eliminates the need for separate external electrodes on both surfaces, reducing thickness while maintaining reliable electrical connection
Solution Approach 2:
The solid electrolyte layer serves multiple functions: it acts as the capacitive element on the first surface, provides electrical connection through the thickness direction, and serves as the external electrode on the opposite surface. This multi-functionality reduces the number of separate components needed, enabling a thinner overall design
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 enhances capacitance efficiency and allows for a thinner, more compact solid electrolytic capacitor by utilizing both sides of the valve action metal base for capacitance generation and minimizing non-capacitance volume, thereby increasing the capacitance-to-volume ratio.
Implementation Method 1
a valve action metal base with a core portion having a first principal surface and a second principal surface, a first porous portion on the first principal surface and a second porous portion on the second principal surface
Implementation Method 2
the first dielectric layer and the first solid electrolyte layer forming a first capacitance portion at a principal surface of the solid electrolytic capacitor, and the second dielectric layer and the second solid electrolyte layer forming a second capacitance portion
Data Source
AI summary
A solid electrolytic capacitor that includes: a capacitor element having a valve action metal base with a core portion, a first porous portion and a second porous portion, a first dielectric layer on the first porous portion, a first solid electrolyte layer on the first dielectric layer, a first conductor layer on the first solid electrolyte layer, a second dielectric layer on the second porous portion, and a second solid electrolyte layer on the second dielectric layer, the first dielectric layer and the first solid electrolyte layer constituting a first capacitance portion, and the second dielectric layer and the second solid electrolyte layer constituting a second capacitance portion; a cathode through electrode electrically connecting the first capacitance portion to a cathode external electrode; and a connection portion connecting the second capacitance portion to the first capacitance portion.