Solid Electrolytic Capacitor Ionic Compound Impregnation
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Solution Overview
Problem
It is challenging to effectively capture and enhance the restoration capability of ionic liquids in solid electrolytes within dielectric films of solid electrolytic capacitors, which limits their electrical properties.
Innovation Solution
A method for manufacturing solid electrolytic capacitors involves forming a dielectric film on a positive electrode body, impregnating it with a melted ionic compound having a melting point of 30°C or higher, and then solidifying it to create a conductive polymer-based solid electrolyte layer, ensuring the ionic compound is trapped and can restore defects in the dielectric film during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an ionic liquid is added to a solid electrolyte to improve restoration capability, then the restoration capability in the dielectric film is improved, but the ionic liquid may not be effectively captured and maintained at high concentration
Solution Approach 1:
The patent utilizes phase transitions of the ionic compound by heating it to a melted state for impregnation into the porous electrode body, then cooling it to solidify and trap the ionic compound within the porous structure. This phase transition approach enables effective capture and maintenance of high ionic compound concentration in the solid electrolyte layer, resolving the contradiction between improving restoration capability and maintaining high concentration.
Solution Approach 2:
The patent changes the physical state parameter of the ionic compound from solid to liquid (melted state) during the manufacturing process to enable impregnation, then reverses it back to solid state for containment. This parameter change strategy allows the ionic compound to be effectively incorporated into the solid electrolyte while maintaining high concentration, thereby improving restoration capability without losing the ionic compound.
2Ease of manufacture
If a solid electrolyte layer is formed on the positive electrode body, then the capacitor structure is completed, but the restoration capability in the dielectric film remains insufficient
Solution Approach 1:
The patent creates a composite solid electrolyte layer by combining a conductive polymer with an ionic compound. The conductive polymer provides the solid electrolyte matrix structure, while the incorporated ionic compound enhances restoration capability. This composite material approach allows the capacitor structure to be completed while simultaneously improving restoration capability in the dielectric film.
Solution Approach 2:
The ionic compound acts as an intermediary substance that mediates between the solid electrolyte matrix and the dielectric film. It is impregnated into the porous electrode body and positioned at the interface with the dielectric film, where it can effectively restore defects in the dielectric film while maintaining the overall capacitor structure.
3Productivity
If the ionic compound is impregnated in melted state, then the impregnation efficiency is improved, but the process complexity increases due to heating and cooling steps
Solution Approach 1:
The patent employs phase transitions of the ionic compound as an integral part of the manufacturing process. By heating the ionic compound to its melting point for impregnation and then cooling it to solidify, the process achieves high impregnation efficiency while the complexity is managed through the inherent properties of the ionic compound's phase behavior. This approach transforms process complexity into a controlled physical transformation sequence.
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 results in solid electrolytic capacitors with improved restoration capability and electrical properties, maintaining high ionic compound concentration and preventing leakage, thus enhancing capacitance and reducing equivalent series resistance.
Implementation Method 1
heating and melting an ionic compound; impregnating the positive electrode body with the melted ionic compound; cooling and solidifying the ionic compound after impregnating
Implementation Method 2
heating and melting an ionic compound; cooling and solidifying the ionic compound after impregnating
Implementation Method 3
impregnating the positive electrode body with the melted ionic compound
Data Source
AI summary
A method for manufacturing a solid electrolytic capacitor which includes a capacitor element including: an positive electrode body with a dielectric film formed on a surface thereof; and a solid electrolyte layer formed over the positive electrode body, the method including the steps of: forming the dielectric film on the surface of the positive electrode body; forming the solid electrolyte layer on the dielectric film; heating and melting an ionic compound; impregnating the positive electrode body, on which the solid electrolyte layer is formed, with the melted ionic compound; and cooling and solidifying the ionic compound after impregnating the positive electrode body with the ionic compound.