Solid Electrolytic Capacitor Imide Binder Cathode

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Solution Overview

Problem

Conventional solid electrolytic capacitors face issues with characteristic deterioration due to difficulties in controlling the thickness of the carbon layer and the presence of gaps between the conductive polymer and silver paste layers, leading to reliability and performance problems.

Innovation Solution

The use of an imide-based polymer as a binder resin in the silver paste layer allows for closer contact with the solid electrolytic layer, reducing gaps and omitting the need for a carbon layer, thereby improving capacitor characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a carbon layer is formed to improve contact between the silver paste layer and solid electrolytic layer, then contact quality improves, but the thickness control becomes difficult and cracks occur during exterior covering

Engineering Contradiction:

Improvecontact quality between cathode layer and solid electrolytic layerVSAvoidthickness control of carbon layer

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention extracts and eliminates the carbon layer from the capacitor structure. By forming the silver paste layer to directly contact the solid electrolytic layer without an intermediate carbon layer, the patent resolves the thickness control and cracking issues while maintaining contact quality through direct bonding between the silver paste and solid electrolytic layer

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention uses a composite silver paste layer containing silver particles, conductive polymer particles, and binder resin that directly contacts the solid electrolytic layer. This composite material formulation enables effective contact without requiring a separate carbon layer, solving both the contact quality and manufacturing precision problems

Inventive Principle:

Principle #40Composite materials

2Device complexity

If the carbon layer is omitted and silver paste layer is formed directly on conductive polymer layer, then manufacturing complexity reduces, but gaps are left between layers causing characteristic deterioration

Engineering Contradiction:

Improvenumber of layers in cathode structureVSAvoidcontact quality between cathode layer and solid electrolytic layer

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The invention changes the material parameters of the silver paste layer by incorporating conductive polymer particles and specific binder resins. This parameter modification enables the silver paste layer to adhere directly to the solid electrolytic layer without forming gaps, achieving both reduced complexity and maintained reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The silver paste layer is formulated as a composite material containing silver particles for conductivity, conductive polymer particles for adhesion, and binder resin for structural integrity. This composite formulation allows direct contact with the solid electrolytic layer without gaps, eliminating the need for a carbon layer while maintaining contact quality

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8559165B2Solid electrolytic capacitor

Publication Date: 2013.10.15 SANYO ELECTRIC CO LTD

AI summary

A solid electrolytic capacitor includes an anode element, a dielectric layer, a solid electrolytic layer, and a cathode layer. The dielectric layer is formed on the anode element. The solid electrolytic layer is formed on the dielectric layer. The cathode layer is formed so as to contact the solid electrolytic layer. The cathode layer is a silver paste layer having an imide-based polymer as a binder resin. A solid electrolytic capacitor that can be improved in characteristics can thus be obtained.