Linear-Hyperbranched Polymers as Performance Additives for Solid Electrolytic Capacitors

Patent metadata

Field	Value
Publication number	US-2016254099-A1
Application number	US-201615149720-A
Country	US
Kind code	A1
Filing date	May 9, 2016
Priority date	Dec 7, 2012
Publication date	Sep 1, 2016
Grant date	—

Abstract

Provided herein is an improved capacitor and a method for forming an improved capacitor. The method includes providing an anode and forming a dielectric on the anode. A linear-hyperbranched polymer is formed and a conductive polymer dispersion is prepared comprising at least one conducting polymer, one polyanion and the linear-hyperbranched polymer. A layer of the conductive polymer dispersion if formed wherein said dielectric is between the anode and the layer.

First claim

1 - 34 . (canceled)

35 . A capacitor comprising:
an anode; a cathode wherein said cathode comprises a linear-hyperbranched polymer; and a dielectric between said anode and said cathode.

36 . The capacitor of claim 35 wherein said anode comprises a valve metal or a conductive compound of said valve metal.

37 . The capacitor of claim 35 wherein said cathode comprises a conductive polymer or manganese dioxide.

38 . The capacitor of claim 35 wherein said dielectric is an oxide of said anode.

39 . The capacitor of claim 35 wherein said linear-hyperbranched polymer comprises a linear portion.

40 . The capacitor of claim 39 wherein said linear portion comprises at least two reactive end groups selected from the group consisting of hydroxyl, amino and epoxy.

41 . The capacitor of claim 39 wherein said linear portion comprises at least one of polyamide-ester-amide, polyesteramide and polyesteramine.

42 . The capacitor of claim 39 wherein said linear portion comprises:

wherein R 21 and R 25 are terminating groups;
R 22 , R 23 and R 24 are independently alkyls or substituted alkyl of 1 to 50 carbons;
n is an integer; and
wherein R 21 , R 22 , R 23 , R 24 , R 25 and n are selected such that the molecular weight of said linear portion is no more than 1000.

43 . The a capacitor of claim 35 wherein said preparing of said linear-hyperbranched polymer is a reaction product of a diol and an anhydride to form a linear portion.

44 . The capacitor of claim 43 wherein said diol is OH—R 1 —OH wherein R 1 is a linear alkyl.

45 . The capacitor of claim 43 wherein said anhydride is defined by:

wherein R 2 is a linear alkyl of 1 to 6 carbons, which may be substituted, or the atoms necessary to form a ring which may be substituted.

46 . The capacitor of claim 45 wherein said ring is an aromatic ring.

47 . The capacitor of claim 43 further comprising reacting with an acrylate wherein said acrylate is defined by:

wherein R 3 is a linear alkyl of 1 to 50 carbons which may be substituted, an ether or polyether which may be substituted.

48 . The capacitor of claim 47 wherein said acrylate is defined by:

wherein R7 is hydrogen or methyl and n is an integer of no more than 10.

49 . The capacitor of claim 47 wherein said acrylate is selected from the group consisting of 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate (HEA), 2,2-bis(hydroxymethyl)propyl acrylate;

50 . The capacitor of claim 43 wherein said linear-hyperbranched polymer is a second reaction product of a hydroxyl amine with said reaction product.

51 . The capacitor of claim 50 wherein said hydroxyl amine is defined by

wherein R 5 and R 5′ are independently selected from linear alkyls of 1-6 carbons which may be substituted.

52 . The capacitor of claim 51 wherein said hydroxyl amine is selected from:

53 . The capacitor of claim 35 wherein said linear-hyperbranched polymer comprises at least Generation 1 branching.

54 . The capacitor of claim 53 wherein said linear-hyperbranched polymer comprises at least Generation 2 branching.

55 . The capacitor of claim 53 wherein said linear-hyperbranched polymer has an acid number of at least 100 to no more than 1000.

56 . The capacitor of claim 55 wherein said linear-hyperbranched polymer has an acid number of no more than 200.

57 . The capacitor of claim 35 wherein said cathode has a performance additive with no more than 10 wt % sulfonate.

58 . The capacitor of claim 57 wherein said performance additive has no more than 0.1 wt % sulfonate.

59 . The capacitor of claim 35 wherein said cathode has a performance additive with no more than 10 wt % primary or secondary amines.

60 . The capacitor of claim 59 wherein said performance additive has no more than 10 wt % primary or secondary amines.

61 . The capacitor of claim 35 further comprising a cross-linked cathode.

62 . The capacitor of claim 61 wherein said cross-linked cathode is a reaction product of said cathode with a crosslinker.

63 . The capacitor of claim 62 wherein said crosslinker is selected from a silane and a ethylene glycol diglycidyl ether.

64 . The capacitor of claim 63 wherein said crosslinker is selected from the group consisting of:

65 . A capacitor comprising:
an anode; a dielectric coated on the anode; and a cathode comprising a reaction product of a hydroxyl amine with a reaction product of a diol and an anhydride.

66 - 124 . (canceled)

125 . A dispersion for forming a conductive coating on a surface comprising a conductive polymer and a linear-hyperbranched polymer.

126 - 156 .(canceled)

Assignees

• Kemet Electronics Corp

Inventors

• Chacko Antony P
• Sivasankarapillai Gopakumar
• Shi Yaru
• Lessner Philip M

Classifications

• H01G9/15

  Solid electrolytic capacitors (H01G11/00 takes precedence) · CPC title

• H01B1/124

  Intrinsically conductive polymers · CPC title

• C09D5/24

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title

• H01G9/028 Primary

  Organic semiconducting electrolytes, e.g. TCNQ · CPC title

• H01G9/0029

  Processes of manufacture · CPC title