Solid Electrolytic Capacitor with Laminated Conductive Polymer for ESR Reduction
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Solution Overview
Problem
Existing solid electrolytic capacitors fail to sufficiently reduce equivalent series resistance (ESR) in high-frequency regions due to limitations in cathode conductivity and contact resistance between cathode layers, despite previous methods involving conductive polymer films.
Innovation Solution
A solid electrolytic capacitor design featuring a conductive polymer layer with a polypyrrole layer inside the porous body for adhesiveness and a laminated polyethylenedioxythiophene-polypyrrole layer in the outer peripheral part for conductivity, optimizing ESR reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform conductive polymer layer is formed on the dielectric layer, then the manufacturing process is simple, but the ESR cannot be sufficiently reduced due to insufficient conductivity in the outer peripheral region
Solution Approach 1:
The patent applies local quality by forming different conductive polymer layer structures in different regions of the porous body. The inner region (first region) uses a single polypyrrole layer for adhesiveness, while the outer peripheral region (second region) uses a laminated structure of polyethylenedioxythiophene layer followed by polypyrrole layer to enhance conductivity and reduce ESR in that specific area.
Solution Approach 2:
The patent segments the conductive polymer layer into two distinct regions: a first region in the inner part of the porous body and a second region in the outer peripheral part. This segmentation allows each region to have optimized properties - the first region provides structural stability and adhesiveness, while the second region provides enhanced conductivity for ESR reduction.
2Reliability
If contact resistance between cathode layers is reduced through multilayered cathode lamination, then conductivity improves, but the complexity of the cathode structure increases
Solution Approach 1:
The patent applies composite materials by forming a laminated conductive polymer layer with polyethylenedioxythiophene and polypyrrole in the outer peripheral region. This composite structure provides enhanced conductivity that reduces the need for complex multilayered cathode structures, thereby reducing contact resistance while avoiding excessive structural complexity.
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 design significantly reduces ESR by enhancing adhesiveness inside the capacitor and conductivity in the outer peripheral part, improving high-frequency performance.
Implementation Method 1
a dielectric layer formed on the surface in the inside part of the porous body and on the surface in the outer peripheral part thereof
Implementation Method 2
a conductive polymer layer formed on the dielectric layer
Data Source
AI summary
Provided is a solid electrolytic capacitor comprising an anode of a porous body formed of a valve metal or its alloy, a dielectric layer formed on the surface in the inside part of the porous body and on the surface in the outer peripheral part thereof, a conductive polymer layer formed on the dielectric layer, a cathode layer formed on the conductive polymer layer in the outer peripheral part of the porous body, and an anode lead of which one end is embedded inside the anode, wherein the conductive polymer layer in the first region which is in the inside part of the porous body and the periphery around the anode lead as the center is formed of a polypyrrole layer, and the conductive polymer layer in the second region which is the periphery around the first region is formed by laminating a polypyrrole layer on a polyethylenedioxythiophene layer.