Solid Electrolytic Capacitor High Specific Charge Anode
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Solution Overview
Problem
Conventional solid electrolytic capacitors with flake powder anodes have limited capacitance due to low surface area, restricting their performance in high voltage environments.
Innovation Solution
A solid electrolytic capacitor with a sintered porous anode formed from finely divided powder with a specific charge greater than 30,000 μF*V/g and pre-polymerized conductive polymer particles, achieving high breakdown voltage and surge current capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flake powder with specific charge of 10,000-15,000 μF*V/g is used in the anode, then the capacitor can withstand high voltages, but the surface area is limited and capacitance is significantly reduced
Solution Approach 1:
The patent changes the key parameter of specific charge from the conventional 10,000-15,000 μF*V/g to greater than 30,000 μF*V/g by using finely divided powder with controlled particle morphology. This parameter change enables both high breakdown voltage and high surface area to be achieved simultaneously, resolving the technical contradiction between voltage withstand capability and capacitance.
Solution Approach 2:
The patent employs a composite anode structure combining finely divided powder particles with a sintered matrix, creating a material that exhibits both high specific charge and high surface area. The composite nature of the anode allows it to maintain structural integrity at high voltages while providing extensive surface area for capacitance.
2Ease of manufacture
If flake powder anode is used, then manufacturing is simpler, but capacitance is limited due to low surface area
Solution Approach 1:
The patent changes the particle morphology parameter from flake shape to finely divided three-dimensional shape, achieving a specific charge greater than 30,000 μF*V/g. This parameter change increases the surface area available for capacitance while maintaining compatibility with standard sintering and anodizing manufacturing processes.
3Reliability
If conventional materials are used for high voltage capacitors, then breakdown voltage is adequate, but capacitance is significantly limited
Solution Approach 1:
The patent creates a composite capacitor structure where the anode combines finely divided high-specific-charge powder with a sintered matrix, and the solid electrolyte uses pre-polymerized conductive polymer particles. This composite approach enables the capacitor to achieve both high breakdown voltage (adequate for high voltage applications) and high capacitance through increased surface area.
Solution Approach 2:
The patent fundamentally changes the specific charge parameter of the anode material from conventional levels (10,000-15,000 μF*V/g) to enhanced levels (>30,000 μF*V/g). This parameter change allows the capacitor to deliver both adequate breakdown voltage and significantly improved capacitance, eliminating the trade-off present in conventional designs.
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 operates effectively at high voltages (up to 300 volts) and withstands surge currents, offering improved performance in high voltage applications with enhanced breakdown voltage and capacitance.
Implementation Method 1
The anode is formed from a finely divided powder having a specific charge of greater than about 30,000 μF*V/g
Implementation Method 2
anodically oxidizing the sintered pellet to form a dielectric layer that overlies the anode
Implementation Method 3
The solid electrolyte comprises a plurality of pre-polymerized conductive polymer particles
Data Source
AI summary
A solid electrolytic capacitor that comprises a sintered porous anode, a dielectric layer that overlies the anode body, and a solid electrolyte overlying the dielectric layer is provided. The anode is formed from a finely divided powder (e.g., nodular or angular) having a relatively high specific charge. Despite the use of such high specific charge powders, high voltages can be achieved through a combination of features relating to the formation of the anode and solid electrolyte. For example, relatively high press densities and sintering temperatures may be employed to achieve “sinter necks” between adjacent agglomerated particles that are relatively large in size, which render the dielectric layer in the vicinity of the neck less susceptible to failure at high forming voltages.