Solid Electrolytic Capacitor with Longitudinal Channels
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Solution Overview
Problem
Conventional solid electrolytic capacitors, particularly those using in situ polymerized polymers, tend to fail at high voltages due to dielectric degradation and exhibit significant capacitance loss and fluctuation in humid environments, limiting their performance in high voltage applications.
Innovation Solution
A solid electrolytic capacitor design featuring a sintered porous anode body with longitudinally extending channels and a solid electrolyte composed of pre-polymerized conductive polymer particles, which enhances heat dissipation, reduces carbon content, and maintains low oxygen levels, thereby increasing breakdown voltage and capacitance retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If in situ polymerized polymers are used as solid electrolyte, then low ESR is achieved, but dielectric degradation occurs at high voltages leading to capacitor failure
Solution Approach 1:
The patent changes the chemical composition parameters of the solid electrolyte by incorporating specific additives (ionic liquids, ceramic particles, or polymer blends) into the intrinsically conductive polymer matrix. This modifies the electrolyte's electrical and thermal parameters to withstand high voltage stress while maintaining low ESR, thereby resolving the contradiction between energy loss and reliability at high voltages
Solution Approach 2:
The patent creates a composite solid electrolyte material by combining intrinsically conductive polymer with ionic liquids, ceramic particles, or other polymers. This composite structure leverages the low ESR of the ICP and the high voltage stability of the ionic liquid or ceramic components, simultaneously achieving both low energy loss and high breakdown voltage
2Reliability
If polymer slurry-based capacitors are used, then high voltage performance is improved, but capacitance loss increases in humid environments
Solution Approach 1:
The patent modifies the physical and chemical parameters of the solid electrolyte formulation by controlling polymer concentration, additive ratios, and drying conditions. These parameter changes optimize the electrolyte's hydrophobicity and structural integrity, reducing moisture absorption while maintaining high voltage performance and capacitance stability in humid environments
Solution Approach 2:
The patent employs a solid electrolyte formulation that is inherently stable and resistant to environmental degradation, eliminating the need for additional protective coatings or sealing mechanisms. The electrolyte itself acts as a long-lasting, moisture-resistant component that maintains capacitance without requiring external protection
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 capacitor achieves higher breakdown voltage, improved surge current handling, and minimal capacitance loss, with a wet-to-dry capacitance percentage of 80% or more, ensuring stable performance in high voltage and humid conditions.
Implementation Method 1
The anode body extends in a longitudinal direction and contains a sidewall positioned between a proximal end and an opposing distal end, wherein a longitudinally extending channel is recessed into the sidewall
Implementation Method 2
The solid electrolyte contains a plurality of pre-polymerized conductive polymer particles
Data Source
AI summary
A capacitor for use in relatively high voltage environments is provided. The solid electrolyte is formed from a plurality of pre-polymerized particles in the form of a dispersion. In addition, the anode is formed such that it contains at least one longitudinally extending channel is recessed therein. The channel may have a relatively high aspect ratio (length divided by width), such as about 2 or more, in some embodiments about 5 or more, in some embodiments from about 10 to about 200, in some embodiments from about 15 to about 150, in some embodiments from about 20 to about 100, and in some embodiments, from about 30 to about 60.