Solid Electrolytic Capacitor With Silane Gradient Polymer Layer
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Solution Overview
Problem
Solid electrolytic capacitors face increased occurrences of short circuit and leakage current during manufacturing and high-temperature reflow processes, while maintaining capacitance and suppressing Equivalent Series Resistance (ESR) remains a challenge.
Innovation Solution
A solid electrolytic capacitor with a conductive polymer layer having a double-layer structure, where the concentration of silane compounds varies stepwise along the thickness direction, with a higher concentration in the inner layer than the outer layer, formed using polymerization solutions with different silane compound concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the capacitor is downsized, then it meets the requirements of electronic device miniaturization, but the occurrence of leakage current and short circuit increases
Solution Approach 1:
The patent applies local quality by creating a conductive polymer layer with non-uniform silane compound concentration distribution. The silane compound concentration is higher near the dielectric film interface and lower toward the outer surface, forming localized regions with different functional properties. This gradient structure provides enhanced short circuit suppression at the critical dielectric interface while maintaining overall capacitor miniaturization.
2Reliability
If a conductive polymer layer is formed to suppress short circuit, then short circuit occurrence decreases, but Equivalent Series Resistance (ESR) increases
Solution Approach 1:
The patent employs parameter changes by systematically varying the silane compound concentration within the conductive polymer layer. Specifically, the silane compound concentration is controlled to decrease from the inner region (near dielectric film) to the outer region, creating a concentration gradient. This parameter variation optimizes the balance between short circuit suppression (requiring higher silane concentration) and ESR control (requiring lower silane concentration), resolving the contradiction between these two opposing requirements.
3Reliability
If the silane compound concentration is increased in the conductive polymer layer, then short circuit suppression improves, but ESR increases excessively
Solution Approach 1:
The patent applies local quality by creating a conductive polymer layer with non-uniform silane compound concentration distribution. The silane compound concentration is higher near the dielectric film interface and lower toward the outer surface, forming localized regions with different functional properties. This gradient structure provides enhanced short circuit suppression at the critical dielectric interface while maintaining overall capacitor miniaturization.
Solution Approach 2:
The patent employs parameter changes by systematically varying the silane compound concentration within the conductive polymer layer. Specifically, the silane compound concentration is controlled to decrease from the inner region (near dielectric film) to the outer region, creating a concentration gradient. This parameter variation optimizes the balance between short circuit suppression (requiring higher silane concentration) and ESR control (requiring lower silane concentration), resolving the contradiction between these two opposing requirements.
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
Effectively suppresses short circuit occurrence and maintains intrinsic capacitor characteristics, including capacitance and ESR, while preventing excessive ESR increase.
Implementation Method 1
The silane compound in the first conductive polymer layer and the silane compound in the second conductive polymer layer have respective concentrations different from each other
Implementation Method 2
forming a first conductive polymer layer on the dielectric film by using a first polymerization solution containing a silane compound, and forming a second conductive polymer layer on the first conductive polymer layer by using a second polymerization solution containing a silane compound
Data Source
AI summary
A solid electrolytic capacitor with suppressed occurrence of short circuit is provided. The solid electrolytic capacitor includes an anode body having a surface on which a dielectric film is formed, and a conductive polymer layer formed on the dielectric film. The conductive polymer layer includes at least a first conductive polymer layer formed on the dielectric film and a second conductive polymer layer formed on the first conductive polymer layer. A silane compound in the first conductive polymer layer and the silane compound in the second conductive polymer layer have respective concentrations different from each other.