Solid Electrolytic Capacitor Gel Electrolyte High Temperature Repair
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Solution Overview
Problem
Solid electrolytic capacitors face increased leakage current due to degradation of dielectric oxide films under mechanical and thermal stress, and existing solutions fail to maintain effective oxide film repair at high temperatures, leading to reduced durability and increased equivalent series resistance.
Innovation Solution
A solid electrolytic capacitor design incorporating a conductive polymer layer with a gel of an organic solvent solidified by a chemical gelling agent, which maintains a high melting point to prevent solvent volatilization and sustain oxide film repair over long-term high-temperature use, utilizing a valve metal, oxide film layer, and a solid electrolyte layer with a gel electrolyte formed by impregnating the conductive polymer layer with an organic solvent containing a chemical gelling agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If an organic compound with high boiling point is used in the solid electrolytic capacitor, then the volatility is reduced, but the leakage current remains large and the oxide film repair effect is not sufficient
Solution Approach 1:
The patent uses a composite structure combining conductive polymer and gel electrolyte in the solid electrolyte layer. The conductive polymer provides stable electrical conductivity and forms a protective interface with the oxide film, while the gel electrolyte supplies moisture for oxide film repair. This composite approach allows the system to achieve both low leakage current and effective oxide film repair functionality.
2Reliability
If water is retained in the oxide film repairing layer to repair oxide film defects, then the oxide film repair capability is improved, but water gradually volatilizes under high temperatures reducing durability
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid water to gel form by incorporating gelating agents. This parameter change allows the electrolyte to retain moisture at high temperatures without volatilization, maintaining the oxide film repair capability while improving high-temperature durability. The gel structure prevents water molecules from escaping while still allowing ion transport for repair functions.
3Reliability
If a gelated layer retaining moisture is used as oxide film repairing layer, then the oxide film repair function is improved, but equivalent series resistance increases
Solution Approach 1:
The patent divides the solid electrolyte layer into two distinct functional segments: a conductive polymer layer that provides low electrical resistance and stable conductivity, and a gel electrolyte layer that provides moisture for oxide film repair. This segmentation allows each layer to optimize its specific function without compromising the other, achieving both low ESR and effective oxide film repair capability.
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 solution significantly reduces leakage current and maintains effective oxide film repair even after long-term use at high temperatures, enhancing the durability and reducing equivalent series resistance of the solid electrolytic capacitor.
Implementation Method 1
a gel of an organic solvent solidified with a chemical gelling agent
Implementation Method 2
the aging treatment depends on the moisture absorbing properties of the device
Implementation Method 3
a solid electrolyte layer formed on the oxide film layer, wherein the solid electrolyte layer includes a conductive polymer
Data Source
AI summary
The solid electrolytic capacitor according to the present invention is a solid electrolytic capacitor including a valve metal, an oxide film layer formed on a surface of the valve metal, and a solid electrolyte layer formed on the oxide film layer, wherein the solid electrolyte layer contains a conductive polymer and a gel of an organic solvent solidified with a chemical gelling agent.