Vertical stack approach in low profile aluminum solid electrolytic capacitors

Patent metadata

Field	Value
Publication number	US-9576734-B2
Application number	US-201314070941-A
Country	US
Kind code	B2
Filing date	Nov 4, 2013
Priority date	Dec 14, 2011
Publication date	Feb 21, 2017
Grant date	Feb 21, 2017

Abstract

An improved capacitor and method of making an improved capacitor is set forth. The capacitor has planer anodes with each anode comprising a fusion end and a separated end and the anodes are in parallel arrangement with each anode in direct electrical contact with all adjacent anodes at the fusion end. A dielectric is on the said separated end of each anode wherein the dielectric covers at least an active area of the capacitor. Spacers separate adjacent dielectrics and the interstitial space between the adjacent dielectrics and spacers has a conductive material in therein.

First claim

The invention claimed is:

1. A capacitor comprising:
a stack of planer anodes with each anode of said anodes comprising a fusion end and a separated end and said anodes are in parallel arrangement with each anode in direct electrical contact with all adjacent anodes at said fusion end;
a dielectric on said separated end of each said anode wherein said dielectric covers at least an active area of said capacitor;
spacers separating adjacent dielectrics and encasing said stack;
interstitial spaces between said adjacent dielectrics and between adjacent said spacers; and
a conductive polymeric material in said interstitial spaces.

2. The capacitor of claim 1 wherein said interstitial spaces do not contain a conductive carbon layer or a conductive metal layer.

3. The capacitor of claim 1 wherein said conductive material is selected from intrinsically conductive polymers, charge transfer conducting compounds or conductive oxides.

4. The capacitor of claim 3 wherein said conductive material comprises a polythiophene, polypyrrole, or polyaniline or any of their derivatives.

5. The capacitor of claim 4 wherein said conductive material comprises poly 3,4-ethylene dioxythiophene.

6. The capacitor of claim 3 wherein said conductive material comprises manganese dioxide.

7. The capacitor of claim 3 wherein said conductive material is in direct contact with said adjacent dielectrics.

8. The capacitor of claim 1 comprising at least 2 planer anodes to no more than 80 planer anodes.

9. The capacitor of claim 8 comprising at least 8 planer anodes to no more than 40 planer anodes.

10. The capacitor of claim 1 wherein said spacer comprises fibers.

11. The capacitor of claim 10 wherein said fibers have an average cross-sectional size of at least 1 to no more than 100 μm in the diameter direction.

12. The capacitor of claim 10 wherein said fibers have a length of at least 1 to no more than 150 μm.

13. The capacitor of claim 10 wherein said fibers comprise a polymeric material.

14. The capacitor of claim 1 wherein said spacer is a carbonized fiber.

15. The capacitor of claim 14 wherein said carbonized fiber has an average cross-sectional size of at least 1 to no more than 100 μm in the diameter direction.

16. The capacitor of claim 14 wherein said carbonized fiber has an average length of at least 1 to no more than 150 μm.

17. The capacitor of claim 1 wherein said spacers span the separation between said adjacent dielectrics.

18. The capacitor of claim 1 wherein adjacent dielectrics are separated by at least 1 to no more than 100 μm.

19. The capacitor of claim 1 wherein said planer anodes comprise a valve metal or a conductive oxide of a valve metal.

20. The capacitor of claim 19 wherein said planer anode comprises a material selected from the group consisting of Ta, Nb, Al, NbO, Ti, Zr and alloys thereof.

21. The capacitor of claim 1 wherein said conductive material further encases said active region of said capacitor.

22. The capacitor of claim 21 further comprising a conductive carbon layer encasing said conductive material.

23. The capacitor of claim 22 further comprising a conductive metal layer encasing said conductive carbon layer.

24. The capacitor of claim 1 further comprising a cathode external termination in electrical contact with said conductive material and an anode external termination in electrical contact with said anodes.

25. A capacitor comprising:
planer anodes with each anode of said anodes comprising a fusion end and a separated end and said anodes are in parallel arrangement with each anode in direct electrical contact with all adjacent anodes at said fusion end;
a dielectric on said separated end of each said anode wherein said dielectric covers at least an active area of said capacitor and adjacent dielectrics are separated by at least 1 to no more than 100 μm;
spacers between adjacent dielectrics;
interstitial spaces between said adjacent dielectrics and around said spacers; and
a conductive material in said interstitial spaces.

26. The capacitor of claim 25 wherein said interstitial spaces do not contain a conductive carbon layer or a conductive metal layer.

27. The capacitor of claim 25 wherein said conductive material is selected from intrinsically conductive polymers, charge transfer conducting compounds or conductive oxides.

28. The capacitor of claim 27 wherein said conductive material comprises a polythiophene, polypyrrole, or polyaniline or any of their derivatives.

29. The capacitor of claim 28 wherein said conductive material comprises poly 3,4-ethylene dioxythiophene.

30. The capacitor of claim 27 wherein said conductive material comprises manganese dioxide.

31. The capacitor of claim 27 wherein said conductive material is in direct contact with said adjacent dielectrics.

32. The capacitor of claim 25 comprising at least 2 planer anodes to no more than 80 planer anodes.

33. The capacitor of claim 32 comprising at least 8 planer anodes to no more than 40 planer anodes.

34. The capacitor of claim 25 wherein said spacer comprises fibers.

35. The capacitor of claim 34 wherein said fibers have an average cross-sectional size of at least 1 to no more than 100 μm in the diameter direction.

36. The capacitor of claim 34 wherein said fibers have a length of at least 1 to no more than 150 μm.

37. The capacitor of claim 34 wherein said fibers comprise a polymeric material.

38. The capacitor of claim 25 wherein said spacer is a carbonized fiber.

39. The capacitor of claim 38 wherein said carbonized fiber has an average cross-sectional size of at least 1 to no more than 100 μm in the diameter direction.

40. The capacitor of claim 38 wherein said carbonized fiber has an average length of at least 1 to no more than 150 μm.

41. The capacitor of claim 25 wherein said spacers span the separation between said adjacent dielectrics.

42. The capacitor of claim 25 wherein said planer anodes comprise a valve metal or a conductive oxide of a valve metal.

43. The capacitor of claim 42 wherein said planer anode comprises a material selected from the group consisting of Ta, Nb, Al, NbO, Ti, Zr and alloys thereof.

44. The capacitor of claim 25 wherein said conductive material further encases said active region of said capacitor.

45. The capacitor of claim 44 further comprising a conductive carbon layer encasing said conductive material.

46. The capacitor of claim 45 further comprising a conductive metal layer encasing said conductive carbon layer.

47. The capacitor of claim 25 further comprising a cathode external termination in electrical contact with said conductive material and an anode external termination in electrical contact with said anodes.

Assignees

• Kemet Electronics Corp

Inventors

• Ning Liancai
• Ya Qun
• Jin Xincheng
• Reed Erik Karlsen
• Stolarski Chris

Classifications

• H01G9/02 Primary

  Diaphragms; Separators · CPC title

• H01G9/0425

  specially adapted for cathode · CPC title

• H01G4/30 Primary

  Stacked capacitors (H01G4/33 takes precedence) · CPC title

• Y10T29/43

  Electric condenser making · CPC title

• H01G9/15

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