Solid Electrolytic Capacitor Assembly with Resin Filler
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Solution Overview
Problem
Conductive polymer electrolytes in solid electrolytic capacitors are inherently weak, leading to delamination issues, which limits their use in multi-anode capacitors, particularly in applications requiring low equivalent series resistance (ESR) at high operating frequencies.
Innovation Solution
A capacitor assembly comprising two solid electrolytic capacitor elements with an anode, dielectric coating, and conductive polymer electrolyte, where the elements are spaced apart to allow a resinous material to fill the gap, enhancing mechanical stability and electrical performance by limiting expansion and preventing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple capacitor elements are employed to reduce ESR, then electrical performance is improved, but mechanical robustness deteriorates due to delamination of the weak conductive polymer electrolyte
Solution Approach 1:
A resinous material is introduced as an intermediary substance between the conductive polymer electrolyte and the external environment. This resin fills the spaces between adjacent capacitor elements and provides mechanical support to the inherently weak conductive polymer electrolyte, preventing delamination while maintaining the multi-element configuration needed for low ESR performance
Solution Approach 2:
The capacitor assembly utilizes a composite structure combining the conductive polymer electrolyte with the resinous material. The resin acts as a structural matrix that reinforces the conductive polymer, creating a composite system that exhibits both the electrical properties of the conductive polymer and the mechanical strength of the resin, enabling reliable multi-anode capacitor construction
2Loss of energy
If conductive polymer electrolyte is applied to reduce ESR, then electrical performance is improved, but mechanical strength deteriorates causing delamination during formation or operation
Solution Approach 1:
The resinous material is applied beforehand to provide mechanical cushioning and support to the conductive polymer electrolyte before delamination can occur. This preventive measure reinforces the weak electrolyte layer during the formation process and subsequent operation, preventing the delamination that would otherwise occur due to the inherent weakness of the conductive polymer
Solution Approach 2:
The resin serves as a protective intermediary layer that reinforces the conductive polymer electrolyte, providing the mechanical strength needed to prevent delamination while allowing the conductive polymer to maintain its low ESR electrical properties
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 provides a capacitor assembly with improved mechanical robustness and electrical properties, including low ESR, high capacitance, and high dielectric breakdown voltage, suitable for applications like switch-mode power supplies and digital circuits.
Implementation Method 1
a dielectric coating overlying the anode that is formed by anodic oxidation
Implementation Method 2
A resinous material substantially fills the space defined between the first capacitor element and the second capacitor element
Data Source
AI summary
An integrated capacitor assembly that contains at least two solid electrolytic capacitor elements electrically connected to common anode and cathode terminations is provided. The capacitor elements contain an anode, a dielectric coating overlying the anode that is formed by anodic oxidation, and a conductive polymer solid electrolyte overlying the dielectric layer. The capacitor elements are spaced apart from each other a certain distance such that a resinous material can fill the space between the elements. In this manner, the present inventors believe that the resinous material can limit the expansion of the conductive polymer layer to such an extent that it does not substantially delaminate from the capacitor element. In addition to possessing mechanical stability, the capacitor assembly also possesses a combination of good electrical properties, such as low ESR, high capacitance, and a high dielectric breakdown voltage.