WO2001016972A1 - Conductive polymer capacitor and method for making same - Google Patents

Conductive polymer capacitor and method for making same Download PDF

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Publication number
WO2001016972A1
WO2001016972A1 PCT/US1999/029672 US9929672W WO0116972A1 WO 2001016972 A1 WO2001016972 A1 WO 2001016972A1 US 9929672 W US9929672 W US 9929672W WO 0116972 A1 WO0116972 A1 WO 0116972A1
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WO
WIPO (PCT)
Prior art keywords
conductive polymer
layer
cresol
anode
conductive
Prior art date
Application number
PCT/US1999/029672
Other languages
French (fr)
Inventor
Alexander Bluvstein
Gerovich Vera
Alexander Osherov
Vitaly Strokin
Original Assignee
Vishay Intertechnology, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vishay Intertechnology, Inc. filed Critical Vishay Intertechnology, Inc.
Priority to AU27091/00A priority Critical patent/AU2709100A/en
Priority to EP99968887A priority patent/EP1218897A1/en
Publication of WO2001016972A1 publication Critical patent/WO2001016972A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
    • H01G9/004—Details
    • H01G9/022—Electrolytes; Absorbents
    • H01G9/025—Solid electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
    • H01G11/54—Electrolytes
    • H01G11/56—Solid electrolytes, e.g. gels; Additives therein
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/13—Energy storage using capacitors

Definitions

  • the present invention relates to a conductive polymer capacitor and method for making same.
  • Prior solid electrolytic capacitors have been provided from a molded porous body of metal such as tantalum, niobium, or aluminum which serves as an anode for the capacitor.
  • the metal is powdered and is formed by heat and pressure into a solid porous body.
  • An oxide coating is formed over the metal and a solid electrolyte such as maganese dioxide (MnO 2 ) is formed over the dielectric and serves as the cathode of the capacitor.
  • MnO 2 maganese dioxide
  • polymers have been used in forming the cathode solid electrolyte. Examples of the use of polymers as a solid cathode electrolyte are shown in U.S. Patents 5,461,537; 4,780,796; and 5,457,862.
  • a primary object of the present invention is the provision of an improved conductive polymer capacitor and method for making same.
  • a further object of the present invention is the provision of an improved conductive polymer capacitor which achieves very high conductivity of the polymer layers, thereby resulting in a capacitor with lower equivalent series resistance (ESR).
  • a further object of the present invention is the provision of an improved conductive polymer capacitor and method for making same which is more durable in use, more reliable in operation, and more efficient to manufacture.
  • a conductive polymer capacitor having an anode formed from a porous metal body, and including an anode lead extending therefrom.
  • a dielectric layer is formed on the surface of the anode by oxidizing the metal of the anode.
  • a solid electrolyte is formed on the dielectric layer comprised of a first conductive polymer layer formed on the dielectric layer and a second conductive polymer layer formed on the first conductive polymer layer.
  • the first conductive polymer layer is preferably a polypyrrole layer.
  • the second conductive polymer layer comprises a polyaniline layer formed by dipping the metal body having the first conductive polymer layer thereon into a solution of doped polyaniline dissolved in an organic solvent.
  • doped refers to the use of a dopant which is either an electron donor or acceptor in polymer compounds such as polypyrrole, polythiophene, and polyaniline.
  • dopants include, but are not limited to, naphtalenesulfonic acid sodium salt, toluenesulfonic acid sodium salt, and benzenesulfonic acid sodium salt.
  • Other dopants capable of donating or accepting electrons to the polymer compound may be used without detracting from the invention.
  • Numerous organic solvents may be used for the dissolving of the polyaniline before the dipping process. Examples include but are not limited to m-Cresol, p-Cresol, o-Cresol, and Cl-Cresol.
  • inorganic fillers may be included within the polyaniline solution inorganic solvent so that the second conductive layer, once formed by dipping, includes the inorganic filler within the second conductive layer.
  • the inorganic filler may be selected from any of a number of inorganic fillers, including but not limited to graphite, SiO 2 , Al 2 O 3 , SrO 2 , ZrO 2 , MgO, BeO.
  • FIGURES OF THE DRAWINGS Figure 1 is a sectional view of the capacitor of the present invention.
  • Figure 2 is an enlarged sectional view taken along line 2-2 of Figure 1.
  • Capacitor 10 generally designates the capacitor of the present invention.
  • Capacitor 10 includes an anode pellet 12 having an anode lead 14 connected thereto by means of a weld 16.
  • the anode pellet is formed from a powdered metal such as tantalum, niobium, or aluminum.
  • the method for forming the pellet 12 is well known in the art and involves compressing the powdered material into the pellet shape and sintering the pellet to cause it to retain its shape.
  • the pellet 12 includes a plurality of voids interspersed throughout the pellet 12. Coating the surface of the pellet 12 is an oxide coating 18. While this oxide coating 18 is shown schematically in Figure 2, the oxide coating coats the exposed surfaces of the particles within pellet 12 throughout the entire body 12.
  • a first polymer layer 20 is formed on the outer surface of the oxide coating 18, and a second polymer layer 22 is formed on the outside of the first polymer layer 20.
  • a conductive cathode material 24 is formed on the outside surface of the polyaniline layer, and a dielectric coating 26 is formed around the outside of the entire capacitor 10, leaving a portion of the cathode 24 exposed to provide a cathode connecting surface 28 at the bottom of the capacitor.
  • the first step in the formation of cathode 10 is the formation of the metal body 12.
  • This metal body may comprise tantalum, niobium, or aluminum powder which is compressed under pressure and then is sintered to form the anode pellet 12.
  • the pellet 12 is then oxidized in accordance with the processes well known in the art to form the dielectric layer 18 on the surface of the pellet.
  • the dielectric layer 18 is preferably an oxide of the metal powder used for the pellet 12.
  • two polymer layers 20, 22 are formed on the surface of the pellet 12. The formation of the two layers 20, 22 will be described below in detail by way of examples.
  • the first polymer layer 20 is formed by dipping the pellet 12 having the oxide coating 18 thereon into an iron (III) chloride aqueous solution (2-20 wt.%) for 3-15 minutes at room temperature. It is then permitted to dry for 10-20 minutes at 60°-80°C. The pellet is then dipped into a solution of pyrrole (2-5 wt.%) and naphtalenesulfonic acid sodium salt (1-2 wt.%) for 5 minutes at 0°-10°C. The dipped pellet is then permitted to dry for 10-20 minutes at 60°-80°C. After drying the pellet is washed with methanol at room temperature for 5 minutes and is permitted to dry for 10-20 minutes at 60°-80°C. After completion of this drying step a polypyrrole layer is formed for the first polymer layer 20. This polymerization procedure is repeated 5-7 times.
  • the second polymer layer 22 is formed by dipping the pellet into a solution of doped polyaniline (2 wt.%) in m-Cresol for 5 minutes at room temperature.
  • the dopant is camphorsulfonic acid. It is then vacuum dried for 30-60 minutes at
  • Example 2 The formation of the pellet 12 having the oxide layer 18 thereon is the same as described above. Also, the formation of the first polymer layer 20 of a polypyrrole material is the same as described above.
  • the pellet After the formation of the polypyrrole layer the pellet is dipped into a solution of doped polyaniline (2 wt.%) in m-Cresol with inorganic fillers such as S j O 2 or similar fillers for 5 minutes at room temperature. The pellet is then vacuum dried for 30-60 minutes at 60°-90°C.
  • Example 3 The pellet 12, oxide layer 18, and first polymer layer 20 are formed in the manner described above in Examples 1 and 2.
  • the pellet, having the polypyrrole polymer layer formed on the outer surface thereof is dipped into a solution of doped polyaniline (2 wt.%) in m-Cresol with graphite filler for 5 minutes at room temperature, and the pellet is vacuum dried for 30-60 minutes at 60°-90°C.
  • doped polyaniline (2 wt.%) in m-Cresol with graphite filler for 5 minutes at room temperature
  • the pellet is vacuum dried for 30-60 minutes at 60°-90°C.
  • the use of fillers as described above for Examples 2 and 3 permits the fillers to be dispersed throughout the polyaniline layer 22, whereas prior art methods formed the fillers as separate layers rather than embedding them within the polyaniline layer.
  • the oxidant used for forming the polypyrrole layer in the above examples is preferably iron (III) chloride.
  • ferric salts of arylsulfonic acids may be used as oxidant.
  • the preferred dopant for use in the formation of the polyaniline layer in the above examples is camphorsulfonic acid.
  • other acids may be used, including but not limited to, arylsulfonic acids.
  • the solvent for forming the polyaniline layer is preferably m-Cresol, but other solvents may be used such as p-Cresol, o-Cresol or Cl-Cresol.
  • the inorganic fillers described for Example 2 above preferably include SiO 2 .
  • other fillers such as Al 2 O 3 , SnO 2 , ZrO 2 , MgO, and BeO may be used.
  • the process for forming the polypyrrole impregnation is repeated 5-10 cycles so as to form layer 20 of multiple polypyrrole layers.
  • the formation of the polyaniline layer 22 is preferably two cycles so as to form two polyaniline based layers.
  • the above described method achieves a very high conductivity of the multiple polyaniline based layers. This results in capacitors with very low equivalent series resistance (ESR). Of particular importance is the ability to disperse inorganic fillers in the polyaniline layers so as to improve the electrical conductivity of the polyaniline layers.
  • ESR equivalent series resistance

Abstract

A conductive polymer capacitor includes an anode (12) formed from a porous metal body (12) having an anode lead (14) extending therefrom. A dielectric layer (18) is formed by oxidizing a surface of the anode. A solid electrolyte is formed on the dielectric layer and includes first (20) and second (22) polymer layers. The second conductive polymer layer includes a polyaniline layer formed by dipping the metal body (12) having the first conductive layer (20) thereon into a solution of doped polyaniline dissolved in an organic solvent.

Description

TITLE: Conductive Polymer Capacitor And
Method For Making Same
BACKGROUND OF THE INVENTION The present invention relates to a conductive polymer capacitor and method for making same. Prior solid electrolytic capacitors have been provided from a molded porous body of metal such as tantalum, niobium, or aluminum which serves as an anode for the capacitor. The metal is powdered and is formed by heat and pressure into a solid porous body. An oxide coating is formed over the metal and a solid electrolyte such as maganese dioxide (MnO2) is formed over the dielectric and serves as the cathode of the capacitor. In recent years polymers have been used in forming the cathode solid electrolyte. Examples of the use of polymers as a solid cathode electrolyte are shown in U.S. Patents 5,461,537; 4,780,796; and 5,457,862.
In these prior capacitors, two polymer layers are formed. The first polymer is formed by using a chemical oxidant to chemically oxidize and polymerize the polymer on the dielectric layer of the capacitor. Then a second polymer layer is formed using a solution containing an undoped polymer compound polymerized in advance and soluble in an organic solvent. After the formation of the second polymer compound, the second polymer compound is doped to make the undoped polymer compound layer conductive. Therefore, a primary object of the present invention is the provision of an improved conductive polymer capacitor and method for making same.
A further object of the present invention is the provision of an improved conductive polymer capacitor which achieves very high conductivity of the polymer layers, thereby resulting in a capacitor with lower equivalent series resistance (ESR). A further object of the present invention is the provision of an improved conductive polymer capacitor and method for making same which is more durable in use, more reliable in operation, and more efficient to manufacture.
SUMMARY OF THE INVENTION The foregoing objects may be achieved by a conductive polymer capacitor having an anode formed from a porous metal body, and including an anode lead extending therefrom. A dielectric layer is formed on the surface of the anode by oxidizing the metal of the anode. A solid electrolyte is formed on the dielectric layer comprised of a first conductive polymer layer formed on the dielectric layer and a second conductive polymer layer formed on the first conductive polymer layer. The first conductive polymer layer is preferably a polypyrrole layer. The second conductive polymer layer comprises a polyaniline layer formed by dipping the metal body having the first conductive polymer layer thereon into a solution of doped polyaniline dissolved in an organic solvent.
As used herein the term "doped" refers to the use of a dopant which is either an electron donor or acceptor in polymer compounds such as polypyrrole, polythiophene, and polyaniline. Numerous types of dopants are well known in the art of making capacitors, and include, but are not limited to, naphtalenesulfonic acid sodium salt, toluenesulfonic acid sodium salt, and benzenesulfonic acid sodium salt. Other dopants capable of donating or accepting electrons to the polymer compound may be used without detracting from the invention. Numerous organic solvents may be used for the dissolving of the polyaniline before the dipping process. Examples include but are not limited to m-Cresol, p-Cresol, o-Cresol, and Cl-Cresol.
In one form of the invention inorganic fillers may be included within the polyaniline solution inorganic solvent so that the second conductive layer, once formed by dipping, includes the inorganic filler within the second conductive layer. The inorganic filler may be selected from any of a number of inorganic fillers, including but not limited to graphite, SiO2, Al2O3, SrO2, ZrO2, MgO, BeO.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS Figure 1 is a sectional view of the capacitor of the present invention.
Figure 2 is an enlarged sectional view taken along line 2-2 of Figure 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings the numeral 10 generally designates the capacitor of the present invention. Capacitor 10 includes an anode pellet 12 having an anode lead 14 connected thereto by means of a weld 16. The anode pellet is formed from a powdered metal such as tantalum, niobium, or aluminum. The method for forming the pellet 12 is well known in the art and involves compressing the powdered material into the pellet shape and sintering the pellet to cause it to retain its shape. The pellet 12 includes a plurality of voids interspersed throughout the pellet 12. Coating the surface of the pellet 12 is an oxide coating 18. While this oxide coating 18 is shown schematically in Figure 2, the oxide coating coats the exposed surfaces of the particles within pellet 12 throughout the entire body 12.
A first polymer layer 20 is formed on the outer surface of the oxide coating 18, and a second polymer layer 22 is formed on the outside of the first polymer layer 20. A conductive cathode material 24 is formed on the outside surface of the polyaniline layer, and a dielectric coating 26 is formed around the outside of the entire capacitor 10, leaving a portion of the cathode 24 exposed to provide a cathode connecting surface 28 at the bottom of the capacitor.
The first step in the formation of cathode 10 is the formation of the metal body 12. This metal body may comprise tantalum, niobium, or aluminum powder which is compressed under pressure and then is sintered to form the anode pellet 12. The pellet 12 is then oxidized in accordance with the processes well known in the art to form the dielectric layer 18 on the surface of the pellet. The dielectric layer 18 is preferably an oxide of the metal powder used for the pellet 12. After the formation of the oxide layer 18, two polymer layers 20, 22 are formed on the surface of the pellet 12. The formation of the two layers 20, 22 will be described below in detail by way of examples.
EXAMPLE 1 The first polymer layer 20 is formed by dipping the pellet 12 having the oxide coating 18 thereon into an iron (III) chloride aqueous solution (2-20 wt.%) for 3-15 minutes at room temperature. It is then permitted to dry for 10-20 minutes at 60°-80°C. The pellet is then dipped into a solution of pyrrole (2-5 wt.%) and naphtalenesulfonic acid sodium salt (1-2 wt.%) for 5 minutes at 0°-10°C. The dipped pellet is then permitted to dry for 10-20 minutes at 60°-80°C. After drying the pellet is washed with methanol at room temperature for 5 minutes and is permitted to dry for 10-20 minutes at 60°-80°C. After completion of this drying step a polypyrrole layer is formed for the first polymer layer 20. This polymerization procedure is repeated 5-7 times.
The second polymer layer 22 is formed by dipping the pellet into a solution of doped polyaniline (2 wt.%) in m-Cresol for 5 minutes at room temperature. The dopant is camphorsulfonic acid. It is then vacuum dried for 30-60 minutes at
60°-90°C. This step is repeated 2-3 times. This results in the formation of the second polymer layer 22 from as a polyaniline.
Example 2 The formation of the pellet 12 having the oxide layer 18 thereon is the same as described above. Also, the formation of the first polymer layer 20 of a polypyrrole material is the same as described above.
After the formation of the polypyrrole layer the pellet is dipped into a solution of doped polyaniline (2 wt.%) in m-Cresol with inorganic fillers such as SjO2 or similar fillers for 5 minutes at room temperature. The pellet is then vacuum dried for 30-60 minutes at 60°-90°C.
Example 3 The pellet 12, oxide layer 18, and first polymer layer 20 are formed in the manner described above in Examples 1 and 2. The pellet, having the polypyrrole polymer layer formed on the outer surface thereof is dipped into a solution of doped polyaniline (2 wt.%) in m-Cresol with graphite filler for 5 minutes at room temperature, and the pellet is vacuum dried for 30-60 minutes at 60°-90°C. The use of fillers as described above for Examples 2 and 3 permits the fillers to be dispersed throughout the polyaniline layer 22, whereas prior art methods formed the fillers as separate layers rather than embedding them within the polyaniline layer.
The oxidant used for forming the polypyrrole layer in the above examples is preferably iron (III) chloride. However, also ferric salts of arylsulfonic acids may be used as oxidant.
The preferred dopant for use in the formation of the polyaniline layer in the above examples is camphorsulfonic acid. However, other acids may be used, including but not limited to, arylsulfonic acids. The solvent for forming the polyaniline layer is preferably m-Cresol, but other solvents may be used such as p-Cresol, o-Cresol or Cl-Cresol.
The inorganic fillers described for Example 2 above preferably include SiO2. However, other fillers such as Al2O3, SnO2, ZrO2, MgO, and BeO may be used.
In Examples 1-3 above, the process for forming the polypyrrole impregnation is repeated 5-10 cycles so as to form layer 20 of multiple polypyrrole layers. The formation of the polyaniline layer 22 is preferably two cycles so as to form two polyaniline based layers.
The above described method achieves a very high conductivity of the multiple polyaniline based layers. This results in capacitors with very low equivalent series resistance (ESR). Of particular importance is the ability to disperse inorganic fillers in the polyaniline layers so as to improve the electrical conductivity of the polyaniline layers.
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.

Claims

What is claimed is:
1. A conductive polymer capacitor comprising: an anode comprising a porous metal body having an anode lead extending therefrom; a dielectric layer formed by oxidizing a surface of said anode; a solid electrolyte formed on said dielectric layer comprised of a first conductive polymer layer formed on said dielectric layer and a second conductive polymer layer formed on said first conductive polymer layer; said second conductive polymer layer comprising a polyaniline layer formed by dipping said metal body having said first conductive layer thereon into a solution of doped polyaniline dissolved in an organic solvent.
2. A conductive polymer capacitor according to claim 1 wherein said organic solvent is selected from the group consisting essentially of m-Cresol, p-Cresol, O-Cresol, and Cl- Cresol.
3. A conductive polymer capacitor according to claim 1 wherein said doped polyaniline is doped with a dopant selected from the group consisting essentially of arylsulfonic acids and camphorsulfonic acid.
4. A conductive polymer capacitor according to claim 1 and further comprising an inorganic filler within said second conductive layer.
5. A conductive polymer capacitor according to claim 4 wherein said inorganic filler is selected from the group consisting essentially of SiO2, Al2O3, SnO2, ZrO2, MgO, and BeO.
6. A conductive polymer capacitor according to claim 4 wherein said inorganic filler comprises graphite.
7. A conductive polymer capacitor according to claim 1 wherein said first conductive polymer layer comprises a polypyrrole layer.
8. A method for forming a conductive polymer capacitor comprising: forming an anode from a porous metal body; connecting an anode lead to said porous metal body; oxidizing a surface of said anode to form a dielectric layer thereon; forming a first conductive polymer layer on said dielectric layer; forming a second conductive polymer layer on said first conductive polymer layer by dipping said metal body having said dielectric layer and said first conductive layer thereon into a solution of doped polyaniline dissolved in an organic solvent.
9. A method according to claim 8 and further comprising forming said doped polyaniline by using a dopant selected from the group consisting essentially of arylsulfonic acid and camphorsulfonic acid.
10. A method according to claim 8 and further comprising dissolving said doped polyaniline in said organic solvent wherein said organic solvent is selected from the group consisting essentially of m-Cresol, P-Cresol, o-Cresol, and Cl-Cresol.
11. A method according to claim 8 and further comprising forming said first conductive polymer layer from polypyrrole.
12. A method according to claim 8 and further comprising placing an inorganic filler within said organic solvent before said dipping step whereby said inorganic filler is within said second conductive polymer layer after said dipping step.
13. A method according to claim 12 wherein said inorganic filler is selected from the group consisting essentially of SiO2, Al2O3, SnO2, ZrO2, MgO, and BeO.
14. A method according to claim 12 wherein said inorganic filler comprises graphite.
PCT/US1999/029672 1999-08-31 1999-12-14 Conductive polymer capacitor and method for making same WO2001016972A1 (en)

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AU27091/00A AU2709100A (en) 1999-08-31 1999-12-14 Conductive polymer capacitor and method for making same
EP99968887A EP1218897A1 (en) 1999-08-31 1999-12-14 Conductive polymer capacitor and method for making same

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US38623799A 1999-08-31 1999-08-31
US09/386,237 1999-08-31

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EP0697705A1 (en) * 1994-08-16 1996-02-21 Nec Corporation Solid electrolyte capacitor using polyaniline doped with disulfonic acid
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EP1746613A1 (en) * 2005-07-20 2007-01-24 H.C. Starck GmbH & Co. KG Electrolytic capacitors having polymeric outer layer and process of their production
US7411779B2 (en) 2005-07-20 2008-08-12 H.C. Starck Gmbh Electrolytic capacitors with a polymeric outer layer and process for the production thereof
WO2010089111A1 (en) * 2009-02-05 2010-08-12 H.C. Starck Clevios Gmbh Process for producing electrolytic capacitors with a polymeric outer layer
EP2750152A1 (en) * 2009-02-05 2014-07-02 Heraeus Precious Metals GmbH & Co. KG Process for producing electrolytic capacitors with a polymeric outer layer
US8882856B2 (en) 2009-02-05 2014-11-11 Heraeus Precious Metals Gmbh & Co. Kg Process for producing electrolytic capacitors with a polymeric outer layer
US9111680B2 (en) 2009-02-05 2015-08-18 Heraeus Precious Metals Gmbh & Co. Kg Process for producing electrolytic capacitors with a polymeric outer layer
US20230140133A1 (en) * 2021-10-28 2023-05-04 Samsung Electro-Mechanics Co., Ltd. Tantalum capacitor

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US6451074B2 (en) 2002-09-17
AU2709100A (en) 2001-03-26
EP1218897A1 (en) 2002-07-03

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