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Solid electrolytic capacitor and method for manufacturing the same
| Details |
Inventors: Yoshida, Tsunenori; Shimada, Mikinari; Nakada, Yasuhiko;
Assignee: Matsushita Electric Industrial Co., Ltd. (Osaka, JP)
Primary Examiner: Dinkins; Anthony
Assistant Examiner:
Attorney, Agent or Firm: Merchant & Gould P.C.
The present invention provides a solid electrolyte capacitor with which both higher capacitance and lower ESR are achieved, as well as a method for manufacturing the same. The manufacturing method includes a step of forming, in a first solution, a first conductive polymer film serving as a portion of a conductive polymer layer, and a step of forming, in a second solution whose pH is lower than the pH of the first solution, a second conductive polymer film serving as another portion of the conductive polymer layer. The first conductive polymer film and the second conductive polymer film are both formed by electrolytic oxidative polymerization or by chemical oxidative polymerization. Thus, the conductive polymer layer includes a first conductive polymer film made of a plurality of particles, and a second conductive polymer film having an average particle size that is larger than the average particle size of those plurality of particles. The second conductive polymer film is formed such that it covers the apertures of the plurality of pores formed in the anode conductor, and the first conductive polymer film is formed such that at least a portion thereof is disposed inside the plurality of pores, or it is arranged as an outermost film of the conductive polymer layer. |
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DETAILED DESCRIPTION In order to address these problems, according to the present invention, a method for manufacturing a solid electrolytic capacitor including an anode conductor that is made of a valve metal, a dielectric layer that is formed on a surface of the anode conductor, and a solid electrolyte that is formed on a surface of the dielectric layer and includes a conductive polymer layer, includes a step of forming, in a first solution, a first conductive polymer film serving as a portion of the conductive polymer layer; and a step of forming, in a second solution whose pH is lower than the pH of the first solution, a second conductive polymer film serving as another portion of the conductive polymer layer; wherein the first conductive polymer film and the second conductive polymer film are both formed by electrolytic oxidative polymerization.
It is also possible to form the first and the second conductive polymer film by chemical oxidative polymerization instead of electrolytic oxidative polymerization.
In accordance with the present invention, a solid electrolytic capacitor includes an anode conductor that is made of a valve metal; a dielectric layer that is formed on a surface of the anode conductor; and a solid electrolyte that is formed on a surface of the dielectric layer and includes a conductive polymer layer.
The anode conductor includes a plurality of pores.
The conductive polymer layer comprises a first conductive polymer film made of a plurality of particles, and a second conductive polymer film having an average particle diameter that is larger than the average particle diameter of the plurality of particles.
The second conductive polymer film is formed such that it covers the plurality of pores.
The first conductive polymer film is formed such that at least a portion thereof is disposed inside the plurality of pores, or the first conductive polymer film is arranged as an outermost film of the conductive polymer layer.
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Metal Working 
