Solid electrolytic capacitor with interlayer crosslinking

Patent metadata

Field	Value
Publication number	US-9312074-B2
Application number	US-201313777769-A
Country	US
Kind code	B2
Filing date	Feb 26, 2013
Priority date	Feb 27, 2012
Publication date	Apr 12, 2016
Grant date	Apr 12, 2016

Abstract

A method for preparing a solid electrolytic capacitor and an improved solid electrolytic capacitor is provided. The method includes providing an anode, forming a dielectric on the anode and forming a cathode on the dielectric wherein the cathode comprises interlayers. At least one interlayer comprises a monomer, oligomer or polymer with multifunctional or multiple reactive groups and an adjacent layer comprises a molecule with crosslinkable functionality. The oligomer or polymer with multifunctional or multiple reactive groups on one layer react with the crosslinkable functionality in the adjacent layer.

First claim

The invention claimed is:

1. A method for preparing a solid electrolytic capacitor comprising:
providing an anode;
forming a dielectric on said anode;
forming a cathode on said dielectric wherein said cathode comprises interlayers and at least one interlayer comprises a monomer, oligomer or polymer with multifunctional or multiple reactive groups and an adjacent layer comprises a molecule with crosslinkable functionality; and
wherein said oligomer or polymer with multifunctional or multiple reactive groups on one layer react with said crosslinkable functionality in said adjacent layer.

2. The method for preparing a solid electrolytic capacitor of claim 1 wherein at least one said interlayer is selected from intrinsically conductive polymer layers, carbon containing layers and metal containing layers.

3. The method for preparing a solid electrolytic capacitor of claim 2 wherein said metal is selected from silver, copper, and nickel.

4. The method for preparing a solid electrolytic capacitor of claim 1 wherein said reactive groups are selected from hydroxyl, carboxylic acid, epoxy, amine, anhydride functional group, polyester, urethane, amide, imide, and epoxy functional molecules.

5. The method for preparing a solid electrolytic capacitor of claim 1 wherein at least one interlayer is a cathode layer comprising an intrinsically conducting polymer.

6. The method for preparing a solid electrolytic capacitor of claim 5 wherein said intrinsically conducting polymer is polyethylene dioxythiophene.

7. The method for preparing a solid electrolytic capacitor of claim 1 wherein said anode comprises a valve metal preferably selected from the group consisting of Al, Ta, Nb and NbO.

8. A capacitor made by the method of claim 1 .

9. A method for preparing a solid electrolytic capacitor comprising:
providing an anode;
forming a dielectric on said anode;
forming a cathode on said dielectric wherein said cathode comprises interlayers and at least one interlayer comprises a monomer, oligomer or polymer with multifunctional or multiple reactive groups and an adjacent layer comprises a molecule with crosslinkable functionality; and
wherein said oligomer or polymer with multifunctional or multiple reactive groups on one layer react with said crosslinkable functionality in said adjacent layer wherein said crosslinkable functionality is selected from the group consisting of carboxylic, hydroxyl, amine, epoxy, anhydride, isocyanate, imide and amide.

10. A method for preparing a solid electrolytic capacitor comprising:
providing an anode;
forming a dielectric on said anode;
forming a cathode on said dielectric wherein said cathode comprises interlayers and at least one interlayer comprises a monomer, oligomer or polymer with multifunctional or multiple reactive groups and an adjacent layer comprises a molecule with crosslinkable functionality; and
wherein said oligomer or polymer with multifunctional or multiple reactive groups on one layer react with said crosslinkable functionality in said adjacent layer wherein said crosslinkable functionality includes compounds and polymers comprising melamines, isocyanates, epoxies, hexamethoxymelamines, crosslinkable polyesters, glyoxals, furfural aldehydes and melamine formaldehyde condensates.

11. The method for preparing a solid electrolytic capacitor of claim 10 wherein said molecule with crosslinkable functionality is hexakis(methoyxymethyl)melamine.

12. A method for preparing a solid electrolytic capacitor comprising:
providing an anode;
forming a dielectric on said anode;
forming a cathode on said dielectric wherein said cathode comprises interlayers and at least one interlayer comprises a monomer, oligomer or polymer with multifunctional or multiple reactive groups and an adjacent layer comprises a molecule with crosslinkable functionality; and
wherein said oligomer or polymer with multifunctional or multiple reactive groups on one layer react with said crosslinkable functionality in said adjacent layer wherein said oligomer or polymer is a polyester comprising carboxylic acid with an acid number of from about 3 to 100 (mg KOH/g resin solids).

13. The method for preparing a solid electrolytic capacitor of claim 12 wherein said acid number is 20-50 (mg KOH/g resin solids).

14. The method for preparing a solid electrolytic capacitor of claim 12 wherein said acid number is or 50-100 (mg KOH/g resin solids).

15. The method for preparing a solid electrolytic capacitor of claim 12 wherein said oligomer or polymer is a polyester comprising carboxylic acid with an hydroxy number of from about 3 to 200 (mg KOH/g resin solids).

16. The method for preparing a solid electrolytic capacitor of claim 15 wherein said hydroxy number is from about 50 to 100 (mg KOH/g resin solids).

17. A method for preparing a solid electrolytic capacitor comprising:
providing an anode;
forming a dielectric on said anode;
forming a cathode on said dielectric wherein said cathode comprises interlayers and at least one interlayer comprises a monomer, oligomer or polymer with multifunctional or multiple reactive groups and an adjacent layer comprises a molecule with crosslinkable functionality; and
wherein said oligomer or polymer with multifunctional or multiple reactive groups on one layer react with said crosslinkable functionality in said adjacent layer wherein at least one interlayer further comprises organic or inorganic particles of fibers with reactive functional groups.

18. The method for preparing a solid electrolytic capacitor of claim 17 wherein said inorganic particles are selected from nanoparticles, microparticles, functionalized particles, fibers or one interlayer is crosslinked with either functionalized polymer or functionalized particles of an adjacent interlayer.

19. A capacitor comprising:
an anode;
a dielectric on said anode;
a cathode on said dielectric wherein said cathode comprises interlayers wherein at least one interlayer of said interlayers comprises a monomer, oligomer or polymer with multifunctional or multiple groups and an adjacent interlayer comprises a molecule with cross-linked to said multifunctional or multiple groups.

20. The capacitor of claim 19 wherein at least one said interlayer is selected from chemically polymerized intrinsically conducting polymer, electrochemically polymerized intrinsically conducting polymer, and a layer formed from a prepolymerized intrinsically conducting polymer dispersion.

21. The capacitor of claim 19 where said molecule is selected from the group consisting of polyurethane, polyester, polyamide, polyimide, epoxy, butyral and phenolic.

22. The capacitor of claim 21 wherein said polyester has an acid number of from about 3 to 200 and a hydroxy number of from about 3 to 200.

23. The capacitor of claim 19 wherein the polymer with multifunctional or multiple groups is selected from polyester, polyurethane, polyamide, polyamine, polyamide, polyimide, silicone polyester, hydroxyl functional silicone, hydroxyethyl cellulose, polyvinyl alcohol, phenolic, epoxy, butyral, copolymers.

24. A capacitor comprising:
an anode;
a dielectric on said anode;
a cathode on said dielectric wherein said cathode comprises interlayers wherein at least one interlayer of said interlayers comprises a monomer, oligomer or polymer with multifunctional or multiple groups and an adjacent interlayer comprises a molecule with cross-linked to said multifunctional or multiple g

Assignees

• Chacko Antony P
• Hui Danny Yiu Kai
• Kemet Electronics Corp

Inventors

• Chacko Antony P
• Hui Danny Yiu Kai

Classifications

• H01G9/028

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

• H01G9/0425 Primary

  specially adapted for cathode · CPC title

• H01G9/15

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

• H01G11/48

  Conductive polymers · CPC title

• H01G9/0036

  Formation of the solid electrolyte layer · CPC title