JP2005113177A - Metal powder dispersion solution, molding for electrolytic capacitor anode element using the same, electrolytic capacitor anode element, and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance the close contact of a molding for an electrolytic capacitor anode element with a lead wire in a joined body before sintering, and to prevent occurrence of defects such as a short-circuit and current leakage in an electrolytic capacitor. <P>SOLUTION: A metal powder dispersion solution contains valve-action metal powder, binder resin, and solvent. The metal powder dispersion solution in which the standard deviation of the grain size distribution of the dispersed particles of the valve-action metal powder is &ge; 0.41 is coated or printed on a base material. Dried moldings 2 and 4 for the electrolytic capacitor anode element are separated from the base material, and a lead wire 3 formed of the valve-action metal is interposed therebetween to form a joined body 5. The joined body 5 is sintered to manufacture an electrolytic capacitor anode element. <P>COPYRIGHT: (C)2005,JPO&amp;NCIPI

Description

  The present invention relates to a valve action metal powder dispersion, and more particularly to a valve action metal powder dispersion for producing a molded body for an electrolytic capacitor anode element. Furthermore, the present invention relates to an electrolytic capacitor anode element and an electrolytic capacitor manufactured using the electrolytic capacitor anode element, and also relates to a valve action metal powder dispersion, a molded body for an electrolytic capacitor anode element, and a method for manufacturing the electrolytic capacitor anode element.

In recent years, surface mount device miniaturization technology has dramatically advanced, and the mounting technology on component boards in electronic devices such as mobile phones, personal computers, and digital cameras has become increasingly dense. Under such circumstances, various researches have been made on the requirements for downsizing and increasing the capacity of capacitor elements as electronic components.
The capacitor elements that are generally used at present are multilayer ceramic capacitors, aluminum electrolytic capacitors, tantalum electrolytic capacitors, etc., but the tantalum electrolytic capacitors have the features that are particularly small, thin, and capable of large capacity. A lot of research has been done on
Examples of materials having the same characteristics as tantalum metal include so-called valve action metals such as aluminum, niobium, and titanium. However, tantalum metal is used in terms of heat resistance and dielectric film formation. High demand is gained.

As a method of manufacturing an electrolytic capacitor using the above-mentioned valve action metal powder, for example, tantalum metal powder, tantalum is usually used as an anode metal, and a resin that plays a role as a binder and tantalum metal powder are put into a mold. Then, these are pressure processed to produce a chip (hereinafter, this method may be referred to as “dry”).
The chip-formed element manufactured in this way is provided with a component (usually a tantalum lead wire) that becomes an anode terminal. This lead is usually fixed by being planted in a mold and press-molding a tantalum metal powder.
The element obtained by the above process undergoes a process of thermally decomposing and removing unnecessary resin in the element by high-temperature heat treatment in vacuum.
By this step, the resin existing between the tantalum metal powders is removed by thermal decomposition, and a tantalum electrolytic capacitor anode element in the form of a porous body is obtained by welding at the contact point between the tantalum metal powders.

The tantalum electrolytic capacitor anode element thus obtained was placed in an electrolytic bath and subjected to chemical conversion treatment by applying a predetermined DC voltage to form a dielectric film made of tantalum oxide on the porous body surface of the element. Thereafter, a solid electrolyte coating of manganese dioxide or a functional polymer is formed on the coating.
Thereafter, the cathode layer is further treated with carbon, silver paste or the like, and the resin is packaged to obtain a final tantalum electrolytic capacitor.
As the tantalum metal powder normally filled in the mold, those having a particle diameter of 1 to 1000 μm are used.

  In recent years, in order to meet the demands for reducing the size and thickness of electrolytic capacitors, research for further reducing the size of capacitors has been underway. By reducing the thickness in this way, a low equivalent series resistance (ESR) can be realized, and the high frequency characteristics can be greatly improved.

The present inventors have developed a tantalum containing a solvent, a solvent-soluble binder resin, and a tantalum metal powder for the purpose of reducing the size of the tantalum electrolytic capacitor anode element and increasing the capacitance as an electrical property. An electrolytic capacitor anode element obtained by peeling a metal powder dispersion and a coated or printed product coated or printed on the substrate from the substrate and sintering it was proposed (see Patent Document 1, hereinafter, the metal powder as described above). The method using a dispersion may be referred to as “wet” with respect to the dry method). This tantalum metal powder dispersion can be produced by mixing a solvent, a solvent-soluble binder resin, a tantalum metal powder, and additives that are blended as necessary, and dispersing the tantalum metal powder in the solvent. .
By using the metal powder dispersion in this way, a thin coating or printed matter can be obtained, and the electrolytic capacitor anode element can be made thin.
JP 2001-203130 A

A method of manufacturing the electrolytic capacitor anode element by a wet method is as follows. First, as shown in FIG. 1, two sheets of electrolytic capacitor anode element moldings 2 and 4 obtained by coating or printing a metal powder dispersion on a substrate and peeling the dried coating or printed matter from the substrate. Are stacked with the tip portion 3a of the lead wire 3 having a flat tip formed therebetween, and are pressed and brought into close contact with each other as necessary to produce the joined body 5.
Next, the joined body 5 is subjected to high-temperature heat treatment (sintering) to weld the tantalum metal powders and the tantalum metal powder lead wires 3, thereby producing a tantalum electrolytic capacitor anode element 8 as shown in FIG.
Then, the obtained tantalum electrolytic capacitor anode element 8 is subjected to a chemical conversion treatment or the like in the same manner as the tantalum electrolytic capacitor anode element produced by the dry method described above to manufacture a tantalum electrolytic capacitor.

By the way, when manufacturing a tantalum electrolytic capacitor in this way, in the joined body 5 before the high-temperature heat treatment (sintering), the adhesion between the electrolytic capacitor anode element molded bodies 2 and 4 and the lead wire 3 is insufficient. In some cases, the lead wire 3 may come off.
According to the study by the present inventors, the tantalum electrolytic capacitor formed by using the joined body 5 having insufficient adhesion between the electrolytic capacitor anode element molded bodies 2 and 4 and the lead wire 3 is defective in short circuit. In addition, there is a problem that defective leakage current is likely to occur.
If the adhesion between the electrolytic capacitor anode element molded bodies 2 and 4 and the lead wire 3 in the bonded body before sintering is poor, the reason why a short circuit failure or a leakage current failure is likely to occur in the electrolytic capacitor is that the lead wire is strong. This is presumably because the welding due to sintering becomes insufficient because it is not fixed, the welding point of the lead wire and the tantalum powder is easily broken, and the dielectric film formed by the chemical conversion treatment is easily broken.

  The present invention has been made in view of such circumstances, and improves the adhesion between a molded body for an electrolytic capacitor anode element and a lead wire in a bonded body before sintering, and the occurrence of short circuit failure and leakage current failure in the electrolytic capacitor. An object of the present invention is to provide a metal powder dispersion of a valve action metal that can be prevented, an electrolytic capacitor anode element using the same, a molded body for an electrolytic capacitor anode element, and an electrolytic capacitor using the electrolytic capacitor anode element .

The above-mentioned problem is a specific problem when an electrolytic capacitor anode element is manufactured using the metal powder dispersion invented by the present inventors.
As a result of finding out the above-mentioned problem and diligently studying to solve this problem, the present inventors have found that the value of the standard deviation of the particle size distribution based on the volume of the dispersed particles in the metal powder dispersion is an electrolytic capacitor anode in the joined body. The present invention was completed by finding out that it greatly affects the adhesion strength between the element molded body and the lead wire.

  That is, the present invention is a metal powder dispersion containing a valve action metal powder, a binder resin, and a solvent, and the median diameter of the dispersed particles of the valve action metal powder in the particle size distribution on a volume basis is 5 to 100 μm. And a standard deviation σ obtained by the following formula (1), formula (2), and formula (3) based on the particle size distribution is 0.41 or more.

(In the formula, x _j is the j-th value from the smallest when the horizontal axis with a logarithmic scale from 0.08 μm to 3000 μm is equally divided into 50, and q _j is the particle size x _j to x _{j + 1.} (The percentage of the total volume of particles in between the total volume of all particles is expressed as a percentage.)

The metal powder dispersion of the present invention is particularly suitable for production of electrolytic capacitor anode elements.
Then, the metal powder dispersion of the present invention is applied or printed on a substrate and dried to obtain a molded body for an electrolytic capacitor anode element. The molded body for an electrolytic capacitor anode element is peeled from the substrate, An electrolytic capacitor anode element can be obtained by forming a joined body by superposing lead wires made of a working metal therebetween and sintering the joined body. Furthermore, an electrolytic capacitor can be manufactured using this.

According to the present invention, by adjusting the median diameter in the particle size distribution on the volume basis of the dispersed particles to be 5 to 100 μm and the standard deviation to be 0.41 or more, the lead wire in the joined body before sintering is adjusted. The adhesion between the electrolytic capacitor anode element molded body and the lead wire can be improved so that no disconnection occurs. And by producing an electrolytic capacitor using such a joined body, it is possible to prevent occurrence of short circuit failure or leakage current failure in the electrolytic capacitor.
In the metal powder dispersion of the present invention, the standard deviation σ of the particle size distribution based on the volume of the dispersed particles is 0.41 or more, and the particle size distribution is wide. And many fine metal powders having a particle size much smaller than the average particle size of the metal powder fills the voids formed by the metal powder having a larger particle size, and the filling rate of the metal powder powder is improved. doing. For this reason, since the contact point between the lead wire and the metal powder increases and the holding force increases, it is considered that the lead wire of the anode element before sintering does not come off.

The metal powder dispersion of the present invention is a volume of dispersed particles in the metal powder dispersion finally obtained when mixing the valve action metal powder, the binder resin, and the solvent to produce the metal powder dispersion. It can be obtained by controlling the production conditions of the metal powder dispersion so that the median diameter in the standard particle size distribution is 5 to 100 μm and the standard deviation value is 0.41 or more.
Therefore, it is basically unnecessary to add a new process, and it can be manufactured by a simple method.

  In the present invention, as the valve action metal powder, a powder of a valve action metal such as tantalum, aluminum, niobium or titanium can be used. Among these valve action metals, tantalum and niobium are preferable, and tantalum is particularly preferable.

By the way, the valve action metal powder generally used in the above-mentioned dry method such as commercially available metal powder for capacitors is mainly composed of aggregate particles formed by agglomeration of primary particles as a minimum unit. The aggregated particles have a complex outer shape rich in irregularities and at the same time have a very porous shape.
The “dispersed particles” in the present invention refers to a group of valve action metal powder particles contained in a metal powder dispersion, and the aggregate particles or the aggregate particles are crushed. In addition, particles of aggregates that retain a finer porous shape, or primary particles that have been further crushed can be included.

The standard deviation (σ) of the particle size distribution in the present invention is the approximate value of the geometric standard deviation of the dispersed particles with the logarithmic base being 10 in the particle size distribution based on the volume of the dispersed particles, from the particle size distribution data of the particle group. It is what I asked for. The standard deviation (σ) can be obtained from particle size distribution or cumulative distribution data obtained by dividing 0.08 μm to 3000 μm into 50 equal parts when the particle diameter is taken as a logarithmic scale on the horizontal axis.
That the particle size distribution by volume basis, when the ratio of the total volume of the particles belonging to the classification x _j ~x particle size of j + ₁ has on the sum of the volume of all the particles and q%, metal powder dispersion liquid in the present invention The standard deviation (σ) of the dispersed particles can be expressed by the following formulas (1) to (3). This value is an approximation of the geometric standard deviation with a base of 10 regarding the particle size distribution of the individual particles forming the particle group, and the particle size distribution measuring device is usually automatically based on the particle size distribution data. It is a value to be calculated. Further, x _m obtained from the equation (1) is also an approximate value of the geometric mean diameter calculated based on the particle size distribution data.

(In the formula, x _j is the j-th value from the smallest when the horizontal axis with a logarithmic scale from 0.08 μm to 3000 μm is equally divided into 50, and q _j is the particle size x _j to x _{j + 1.} (The percentage of the total volume of particles in between the total volume of all particles is expressed as a percentage.)

Further, the median diameter in the particle size distribution based on volume in the present invention is a value obtained as follows. That is, the median diameter is the total volume of particles having a particle diameter larger than the particle diameter of the particle group as a measurement target, When the ratio of the total to the vertical axis is taken as the vertical axis, a cumulative distribution graph can be obtained as a particle diameter value corresponding to 50% of the vertical axis. Hereinafter, with respect to the median diameter in the particle size distribution on a volume basis, the abbreviation “50% D diameter” and the abbreviation “D ₅₀ ” will be used together.

As a method for obtaining the particle size distribution by measuring the individual particle diameter of the particle group to be measured, for example, a measurement method using a laser diffraction / light scattering method can be used. This measurement method is a method in which a dispersion liquid in which a particle group to be measured is introduced into a dispersion medium and mixed and dispersed is used as the measurement target liquid.
In the present invention, since the particles to be measured are dispersed particles of the valve action metal powder in the metal powder dispersion, the metal powder dispersion is appropriately diluted with the solvent (dispersion medium) contained therein. A measurement method using the laser diffraction / light scattering method can be applied using a diffused liquid as a measurement target liquid.
By using such a measuring apparatus, usually, the standard deviation σ and the 50% D diameter are automatically calculated from the measurement result of the particle diameter of each particle.
In the examples of the present invention, measurement was performed using a laser diffraction flow rate distribution measuring apparatus (SALD-3000S) manufactured by Shimadzu Corporation.

In the present invention, the metal powder dispersion is prepared so that the standard deviation in the particle size distribution on the volume basis of the dispersed particles of the valve action metal powder contained in the metal powder dispersion applied or printed on the substrate is 0.41 or more. To do.
The upper limit of the standard deviation in the particle size distribution on the volume basis of the dispersed particles is not particularly limited. However, if the dispersed particles having a small particle size increase too much, the CV value tends to decrease when an anode element is formed. -0.47 are preferable, More preferably, it is 0.41-0.45.
The standard deviation in the volume-based particle size distribution of the dispersed particles in the metal powder dispersion can be adjusted by changing the crushing force that the valve metal powder undergoes until the preparation of the metal powder dispersion is completed. .

In the present invention, the other parameters related to the dispersed particles of the valve action metal powder contained in the metal powder dispersion must be set within a range that does not significantly deteriorate the manufacturability and characteristics of the electrolytic capacitor anode element and electrolytic capacitor. .
For this reason, the 50% D diameter of the dispersed particles of the valve action metal powder contained in the metal powder dispersion needs to be 5 μm or more and 100 μm or less. The lower limit of the 50% D diameter is preferably 10 μm or more. When the 50% D diameter of the dispersed particles is less than 5 μm, the electrostatic capacity tends to decrease remarkably. Further, in a dispersion containing dispersed particles having a 50% D diameter exceeding 100 μm, it is impossible to stably form a molded body having a film thickness of 500 μm or less, which is an advantage of a wet manufacturing method.
The maximum particle size of the dispersed particles is 0.5 or less when the thickness of the coating or printed material formed by applying or printing the metal powder dispersion on the substrate is 1. Preferably, it is 0.3 or less. If the maximum particle size of the dispersed particles is larger than 0.5, streaks are likely to occur on the surface of the coated material or printed material formed by coating or printing the metal powder dispersion on the substrate, and the molded article for electrolytic capacitor anode elements. And the external appearance of the electrolytic capacitor anode element using the same is impaired.
In particular, when forming a molded body of a thin film having a thickness of about 100 μm, it is preferable that the anode element is formed while keeping the surface of the molded body sufficiently smooth by setting the 50% D diameter to 10 to 25 μm. A CV value can be secured. Particularly for the dispersed particles of the valve action metal powder having such a particle size range, if the content of the dispersed particles having a particle size of 3.5 μm or less is 12 mass% or more, the powder having a particle size of 3.5 μm or less is used. The gap can be effectively filled to increase the holding force of the lead wire in the molded body before sintering, and the lead wire can be prevented from coming off.

Hereinafter, an embodiment of a metal powder dispersion, a molded body for an electrolytic capacitor anode element, an electrolytic capacitor anode element, an electrolytic capacitor, and a manufacturing method thereof will be described.
In this embodiment, the case where preferable tantalum is used as the valve metal will be described as an example.

Step (1): Preparation of Tantalum Metal Powder First, tantalum metal powder to be contained in the metal powder dispersion is prepared so that the standard deviation of the particle size distribution based on the volume is 0.41 or more.
Preferably, tantalum metal powder as a raw material is crushed to prepare tantalum metal powder to be contained in the metal powder dispersion. At this time, the standard deviation of the particle size distribution can be controlled by adjusting the crushing conditions. The larger the crushing force, the larger the standard deviation value.
The tantalum metal powder as the raw material preferably has a purity of 99.5% or more, and the average primary particle diameter is preferably 0.01 to 5.0 μm, particularly 0.01 to 1.0 μm. Is preferred.
As the raw material tantalum metal powder, for example, it is preferable that 50% D diameter is crushed in a solvent. As the powder used for this crushing, tantalum metal powder granulated so as to have a metal powder of about 200 μm, which will be described later, is commercially available as a powder suitable for producing electrolytic capacitors by a dry method, and thus is easily available. It is preferable at this point.

The method for crushing the raw material tantalum metal powder is not particularly limited, but the same solvent as used for preparing the powder dispersion can be appropriately selected and used, but water is preferably used. The amount of the solvent used at the time of crushing needs to be adjusted appropriately according to the crushing apparatus to be used, but if it is too much, the crushing efficiency is bad, and if it is too small, the crusher tends to be overloaded. For example, in the case of a sand mill described later, 35 to 65 parts by mass is preferable with respect to 100 parts by mass of the raw material tantalum metal powder.
Moreover, you may add the additive similar to the additive used for preparation of the metal-powder dispersion mentioned later at the time of crushing, Preferably a dispersing agent can be added.
The apparatus used for crushing is not particularly limited as long as the crushing force can be applied to the raw material tantalum metal powder and the crushing force can be adjusted, and blade type kneaders such as planetary mixers, ball type rotation Various types of apparatuses such as a disperser such as a mill, a sand mill, and an attritor, an ultrasonic disperser, a nanomizer, and a shaker (paint conditioner) can be used.

Specifically, the raw material tantalum metal powder, a solvent, and, if necessary, an additive are added to the apparatus used for crushing, and the geometric standard in the particle size distribution of the tantalum metal powder dispersed in the solvent after crushing. When the condition is further set so that the deviation is 0.41 or more, the 50% D diameter of the dispersed particles of the tantalum metal powder dispersed in the solvent after pulverization is 5 μm to 100 μm. Disintegrate. The maximum particle size is within the range of 0.5 or less when the thickness of the coating or printed material formed by applying or printing the metal powder dispersion on the substrate is 1. It is more preferable to set conditions.
The tantalum metal powder prepared in such a manner that the standard deviation of the particle size distribution on the volume basis and the 50% D diameter fall within the predetermined range is obtained in a state dispersed in a solvent. The dispersion may be used in the preparation step of the dispersion, or may be dried by an appropriate method to obtain a dry powder, and the dry powder may be used in the preparation step of the next dispersion.

Step (2): Preparation of metal powder dispersion The tantalum metal powder, binder resin, solvent, and additives as required in step (1) are mixed to disperse the tantalum metal powder in the solvent. To prepare a metal powder dispersion.

As the binder resin, a binder resin soluble in a solvent can be used. Suitable binder resins include, for example, polyvinyl alcohol resin, polyvinyl acetal resin, butyral resin, phenol resin, acrylic resin, urea resin, vinyl acetate emulsion, polyurethane resin, polyvinyl acetate resin, epoxy resin, melamine resin, alkyd resin, Examples thereof include nitrocellulose resins and natural resins. These resins can be used alone or in admixture of two or more.
The amount of the binder resin used is preferably in the range of 0.01 to 30 parts by mass, particularly preferably in the range of 0.01 to 15 parts by mass, per 100 parts by mass of the tantalum metal powder.

  Solvents include water, alcohols such as methanol, isopropyl alcohol (IPA) and diethylene glycol, cellosolves such as methyl cellosolve, ketones such as acetone, methyl ethyl ketone and isophorone, amides such as N, N-dimethylformamide, acetic acid Examples include, but are not limited to, esters such as ethyl, ethers such as dioxane, chlorinated solvents such as methyl chloride, and aromatic hydrocarbons such as toluene and xylene. These solvents may be used alone or in combination of two or more. The amount of the solvent used is set to such an extent that the step of applying or printing the metal powder dispersion liquid onto the substrate surface can be executed smoothly.

In addition to the tantalum metal powder, the binder resin and the solvent, the metal powder dispersion has physical properties suitable for applying or printing the metal powder dispersion on the surface of the substrate. Various suitable additives can be blended for the purpose of maintaining stability.
Suitable additives include, for example, dispersants such as phthalate esters, phosphate esters and fatty acid esters, plasticizers such as glycols, low-boiling alcohols, antifoaming agents such as silicone-based or non-silicone-based agents, silane coupling agents, A dispersing agent such as a titanium coupling agent, Solsperse, quaternary ammonium salt, or the like may be appropriately used as necessary. The amount of these additives used is preferably in the range of 0.01 to 5.0 parts by mass per 100 parts by mass of the tantalum metal powder. In addition, when these additives are added in one or both of the said process (1) and this process (2), it is preferable that the sum total of those addition amounts is the range of the usage-amount of an additive mentioned above.

If the compounding ratio of this metal powder dispersion is illustrated, for example, the binder resin is 0.01 to 30 parts by mass, preferably 0.01 to 15 parts by mass, and the solvent is 5 to 100 parts by mass of the tantalum metal powder. 160 mass parts and an additive shall be 0-5 mass parts.
The viscosity of the metal powder dispersion is 0.1 to 1000 Pa · s, preferably about 0.1 to 100 Pa · s.

  In this step (2), the tantalum metal powder crushed in the step (1), the binder resin, the solvent, and the like can be mixed and dispersed in the tantalum metal powder crushed in the step (1). A method is used in which the particle size distribution is maintained. For example, there is a method of mixing and dispersing about 0.25 to 5.0 (hours), preferably about 0.5 to 2.0 (hours) using a mixing device such as a planetary mixer.

Step (3): Production of molded body for electrolytic capacitor anode element The metal powder dispersion obtained in the step (2) is applied or printed on a substrate and dried to produce a molded body for electrolytic capacitor anode element. .
By applying or printing the metal powder dispersion on the substrate and drying, the solvent in the metal powder dispersion applied or printed on the substrate is volatilized, and the substrate consists of the metal powder and the binder resin. A coating film (the solvent may remain) remains. The molded body for an electrolytic capacitor anode element of the present invention can be obtained by slitting it to a desired width as necessary and punching it to a predetermined length to obtain a desired size.
The shape of the electrolytic capacitor anode element molded body is not particularly limited, but a thin rectangular parallelepiped is preferable from the viewpoint of ease of processing.

As the base used in this step, it is preferable to use a peelable base in that the molded body for electrolytic capacitor anode elements can be easily peeled while maintaining its shape.
Examples of materials that can be used as the substrate for the peelable substrate include polyethylene film, polypropylene film, polyvinyl chloride film, polyvinylidene chloride film, polyethylene naphthalate film, polyvinyl alcohol film, polyethylene terephthalate (PET) film, polycarbonate film, and nylon. Plastic film or sheet made of film, polystyrene film, ethylene vinyl acetate copolymer film, ethylene vinyl copolymer film or the like; or metal sheet such as aluminum; paper, impregnated paper; composite made of these materials . Among these, a more suitable one is used in consideration of the adhesiveness and peelability due to the combination with the resin in the metal powder dispersion. Even if it is material other than these, if it has required intensity | strength, flexibility, peelability, etc., it can be especially used without a restriction | limiting.
These peelable substrates can be used as peelable substrates as they are, but if a release layer is formed on the surface as described later, the electrolytic capacitor anode element molded body and the substrate can be made smoother. It is preferable because it can be peeled off.

The resin constituting the release layer is preferably compatible with the resin applied to the metal powder dispersion because the release layer and the metal powder layer are easily bonded. Further, a resin that forms a porous metal sintered body with little residual carbon when sintered together with the metal powder is preferable. For example, polyvinyl alcohol resin, polyvinyl acetal resin, butyral resin, and acrylic resin can be preferably used.
The thickness of the release layer is preferably in the range of 1 μm to 20 μm, and in particular, the range of 1 μm to 10 μm is preferable because the amount of residual carbon after sintering is small and the strength of the coating film is appropriately given. When a release layer is provided, stable release is possible with many resins.

  Various coating methods can be used to provide the release layer on the substrate. Examples of the coating method include known roll coating methods, specifically air doctor coat, blade coat, rod coat, extrusion coat, air knife coat, squeeze coat, impregnation coat, reverse roll coat, transfer roll coat, Gravure coat, kiss coat, cast coat, spray coat and the like are used.

Then, the metal powder dispersion prepared in the step (2) is applied or printed on the substrate. When the substrate is a peelable substrate having no release layer, a metal powder dispersion is applied or printed on one surface thereof. On the other hand, when the substrate is a peelable substrate having a release layer, after the coating film to be the release layer is dried, the metal powder dispersion is applied or printed on the coating film.
As the method for applying the metal powder dispersion onto the substrate, various coating methods similar to those used when the release layer is provided on the substrate described above can be used.
Various printing methods can be applied as a method for printing the metal powder dispersion on the substrate. Specifically, the coating material can be printed in a predetermined size on the substrate using a stencil printing method, an intaglio printing method, a lithographic printing method, or the like. In particular, the stencil printing method is preferable because the tantalum electrolytic capacitor anode element can be formed into various shapes such as a desired shape, for example, a rectangular parallelepiped shape, a cylindrical shape, or a comb tooth shape.

Then, preferably after drying with hot air of about 40 to 70 ° C. and volatilizing the solvent in the metal powder dispersion, the electrolytic capacitor having a desired shape is slit or punched to a predetermined width as necessary. A molded body for an anode element is obtained.
The thickness of the obtained molded body for an electrolytic capacitor anode element can be appropriately set depending on the desired capacitance required as a tantalum electrolytic capacitor, and the thickness of the coated or printed material after drying is, for example, several The thickness can be reduced to μm to 0.6 mm, preferably 0.2 mm or less. By using such a coating, it is possible to manufacture an electrolytic capacitor anode element and an electrolytic capacitor that have been thinned to a thickness that cannot be manufactured by a conventional dry method.

  Hereinafter, an embodiment of a method for producing an electrolytic capacitor anode element using a molded body for an electrolytic capacitor anode element will be described with reference to the drawings. Here, an example using a lead wire in which at least a portion embedded in the anode element is formed flat as a lead wire will be described.

Step (4): Formation of Bonded Body First, as shown in FIG. 1, the flat portion 3a of the lead wire 3 having a flat tip is placed on the electrolytic capacitor anode element molded body 2 peeled from the substrate, Further, another electrolytic capacitor anode element molded body 4 is overlaid, and an appropriate pressure treatment is performed as necessary to bring the two electrolytic capacitor anode element molded bodies 2 and 4 and the lead wire 3 into close contact with each other. Then, the joined body 5 for the electrolytic capacitor anode element is formed.

  The lead wire 3 is made of a valve action metal such as tantalum, and at least a portion to be embedded in the anode element or the whole is formed flat. The lead wire 3 is manufactured by pressing and flattening at least a part of a tantalum wire. The thickness and width of the flat portion 3a of the lead wire 3 can be appropriately set in consideration of the thickness of the electrolytic capacitor anode element to be manufactured, the lead wire strength, etc., but preferably the thickness of the molded body 2 and 4 for the electrolytic capacitor anode element It is preferable to flatten to a thickness of 5 to 70%.

Step (5): Sintering Subsequently, the thus obtained joined body 5 for an electrolytic capacitor anode element is appropriately dried if necessary, and then subjected to an organic substance by a heat treatment step at about 300 to 600 ° C. in a vacuum. In addition, the organic substance is completely removed by performing high-temperature heat treatment (sintering) at about 1200 to 1600 ° C. for about 10 to 30 minutes, and the tantalum metal powder is welded together, and the tantalum metal powder As shown in FIG. 2, a tantalum electrolytic capacitor anode having a structure in which a flat portion 3 a of the lead wire 3 is embedded in a thin tantalum porous sintered body 7 as shown in FIG. Element 8 is obtained. The tantalum electrolytic capacitor anode element 8 thus obtained is in a state in which the tantalum porous sintered body 7 and the lead wire 3 are firmly bonded.
When forming a molded body for electrolytic capacitor anode elements, when a peelable substrate having a release layer was used as the substrate, the release layer was peeled off after the molded body for electrolytic capacitor anode elements was peeled from the substrate. Although it is integrated with the molded body for an electrolytic capacitor anode element, the release layer is decomposed and removed by removing organic substances in the sintering step, so the electrolytic capacitor anode element is a porous metal sintered body with less residual carbon. Form.

In order to produce a tantalum electrolytic capacitor using the tantalum electrolytic capacitor anode element 8 thus obtained, the anode element 8 is placed in an electrolytic bath and a predetermined DC voltage is applied to the anode element 8 to form a tantalum electrolytic capacitor. By performing the treatment, a tantalum oxide film is formed on the surface of the anode element 8.
Then, after forming the tantalum oxide film, a manganese dioxide film or a solid electrolyte layer of a functional polymer film is further formed thereon to obtain the anode element 11.

  For example, as shown in FIG. 3, a carbon (graphite) layer and a silver paste layer are formed on the obtained anode element 11, and one end side of the cathode terminal 12 is formed on the surface of the sintered body 7 portion of the anode element 11. Are joined with solder 14, and the tip portion of the lead wire 3 is joined to the anode terminal 13 by spot welding (the welded portion is indicated by reference numeral 15), and is then immersed in a resin solution, for example, or the like. The tantalum electrolytic capacitor 10 is formed by applying the resin sheathing 16.

  The present invention can also be applied to a multilayer electrolytic capacitor. A multilayer electrolytic capacitor can be formed by forming a thin capacitor element by forming an oxide film and a solid electrolyte film on an electrolytic capacitor anode element and laminating them.

In the above embodiment, before preparing the metal powder dispersion, the tantalum metal powder as a raw material is pulverized to obtain a particle size distribution satisfying a specified standard deviation, and this is used as a binder resin so that the particle size distribution does not change. A metal powder dispersion was prepared by mixing with a solvent and the like, but the metal powder dispersion of the present invention is at least when applied or printed on a substrate, the particle size distribution of the dispersed particles in the metal powder dispersion on a volume basis As long as the median diameter and the standard deviation satisfy the prescribed ranges, the metal powder dispersion can be prepared by a method other than the method of this embodiment.
For example, a metal powder dispersion may be prepared by mixing and dispersing tantalum metal powder as a raw material, a binder resin, a solvent, and, if necessary, additives under conditions that cause the tantalum metal powder to be crushed. . In this case, mixing and dispersing so that the median diameter in the particle size distribution on the volume basis of the dispersed particles in the metal powder dispersion obtained after mixing and dispersing satisfies 5 to 100 μm and the standard deviation is 0.41 or more. Control conditions such as. Examples of the kneading / dispersing machine suitable for mixing and dispersing while giving a crushing force to the metal powder include, for example, a roll type kneader such as a stirrer, two rolls, three rolls, a vertical kneader, a pressure kneader, and a planetary. A blade-type kneader such as a mixer, a ball-type rotary mill, a sand mill, a disperser such as an attritor, an ultrasonic disperser, or a nanomizer can be used. A shaker (paint conditioner) or the like is also preferable.

EXAMPLES Next, although an Example is shown and this invention is demonstrated further in detail, this invention is not limited to a following example.
[Examples and Comparative Examples]
As the tantalum metal powder, a commercially available tantalum metal powder (grade with a capacitance of 80000 CV / g) having an average primary particle diameter of 0.5 μm and a 50% D diameter of the entire secondary particles of 226 μm was used.
As an apparatus for crushing, a sand mill provided with a bottomed cylindrical vessel having a capacity of 0.2 liter and a disk-shaped stirring blade perpendicular to the rotation axis was used. The sand mill is usually used for producing an electrolytic capacitor by a wet method by making the amount of dispersion medium input smaller than that when used as a sand mill, preferably about 20 to 40% of the capacity of the vessel. It becomes more suitable for crushing of valve action metal powder. And the crushing force can be increased by increasing the peripheral speed of the stirring blade. Alternatively, the crushing force can be changed by the input amount of the dispersion medium.

  First, in a sand mill vessel, 100 g of tantalum metal powder as raw material, 50 g of water, 10 g of Solspers 20000 (manufactured by Avicia) adjusted to a concentration of 10% by weight as a dispersant, and 60 g of ceramic beads having an outer diameter of 2 mm as a dispersion medium. The metal powder was crushed by rotating the stirring blade. The operating conditions at the time of crushing are the test No. in Table 1 below. Each was set as shown in 1-9. Test No. 1-3, 4-6, and 7-9 changed the stirring time by making the peripheral speed of a stirring blade constant, respectively.

Test No. The metal powder dispersion containing the crushed tantalum metal powder obtained in 1 to 9 was transferred to a flat tray, and freeze-dried. The vacuum freeze-dryer uses “DFM-05AS” manufactured by Nippon Vacuum Co., Ltd., and after drying for 20 hours at a temperature of −40 ° C. and a vacuum degree of 7 to 10 Pa, a surface treatment product of tantalum metal powder is obtained as a bulky dry product. Obtained.
50 g of tantalum metal powder after surface treatment, acrylic resin “NCB-166” (manufactured by Dainippon Ink & Chemicals, Inc., glass transition point−10 ° C.) as binder resin, 5 g (solid content conversion), and toluene (solvent) 50 g Were mixed at a low speed so as not to change the particle size distribution to obtain a tantalum metal powder dispersion.
Test No. About the tantalum metal powder dispersion liquid obtained by using each of the metal powders 1 to 9, the median diameter (50% D diameter) and the standard deviation in the particle size distribution on the volume basis of the dispersed particles are manufactured by Shimadzu Corporation. The measurement was performed using a laser diffraction particle size distribution analyzer SALD-3000S. The results are shown in Table 1 below.

On the other hand, a toluene solution of acrylic resin “BR-88” (manufactured by Mitsubishi Rayon Co., Ltd.) was developed with a # 16 wire bar on a PET film having a thickness of 50 μm to provide a release layer having a thickness of 3 μm.
Next, each metal powder dispersion (test Nos. 1 to 9) obtained above was developed on a PET film provided with a release layer by using an applicator with a depth of 250 μm, dried and thickened. A dry coating film of a metal powder dispersion having a thickness of 150 μm was obtained.
The dried coating PET was slit into a width of 3.6 mm using a slitter and then punched out to a size of 3.6 × 4.4 mm to obtain a molded body for an electrolytic capacitor anode element.
Then, two electrolytic capacitor anode element molded bodies are overlapped with the flattened portion of the lead wire flattened by pressurizing the tip portion of the lead wire having a diameter of 0.2 mm, and further added in a direction in which both are in close contact with each other. The joined body 5 for the electrolytic capacitor anode element having the shape shown in FIG. 1 was produced.

Test No. The joined bodies obtained using each of the metal powder dispersions 1 to 9 were examined for the presence or absence of lead wires.
(Lead wire drop test method)
As shown in FIG. 4, the portion of the lead wire 3 of the joined body 5 is sandwiched between chucks 21 and hung so that the portions of the molded bodies 2, 4 are downward, and then the weight pan 22 with a hook is connected to the molded body 2. After the weight 4 was put on the shoulder portion, a weight 23 was added to the pan so that the total mass became 15 g, and the plate was allowed to stand for 30 seconds.
As a result, a three-stage evaluation was performed according to the state of lead wire missing.

Next, each bonded body 5 is heated to 350 ° C. in a vacuum of 6.6 × 10 ⁻³ Pa (5 × 10 ⁻⁵ torr) and heated for 90 minutes to decompose / decompose the organic substance (binder resin). After removing, and further sintering at 1300 ° C. for 20 minutes, the flat portion 3a of the lead wire 3 is embedded in the thin rectangular parallelepiped porous tantalum 7 as shown in FIG. A tantalum electrolytic capacitor anode element 8 having the above structure was obtained.

  The anode element 8 was anodized by applying a DC voltage of 20 V in a phosphoric acid solution, and its electrical characteristics were measured in accordance with EIAJ RC-2361A to examine the performance. As a result, the test No. In each of the anode elements 1 to 9, the capacitance (CV value) was 90% or more of the CV value of the initial tantalum powder, and it was confirmed that the anode elements had good electrical characteristics.

  From the results in Table 1, the test No. In all of the metal powder dispersions 1 to 9, the 50% D diameter (median diameter) in the particle size distribution of the dispersed particles was 5 to 100 μm, but the standard deviation was less than 0.41. A missing line occurred. That is, it was confirmed that lead wire omission can be prevented when the 50% D diameter (median diameter) is 5 to 100 μm and the standard deviation is 0.41 or more.

It is a figure for demonstrating the example of the manufacturing method of an electrolytic capacitor anode element, and is a perspective view of the joined body obtained by pinching | interposing a lead wire between the molded object for electrolytic capacitor anode elements. It is a perspective view of the electrolytic capacitor anode element obtained by sintering a joined body. It is the schematic which illustrates the electrolytic capacitor obtained using the electrolytic capacitor anode element. It is explanatory drawing of a lead wire missing test method.

Explanation of symbols

2, 4 Formed body for electrolytic capacitor anode element 3 Lead wire 3a Flat portion 5 Joined body 7 Tantalum porous sintered body 8 Tantalum electrolytic capacitor anode element 10 Tantalum electrolytic capacitor 11 Anode element 12 Cathode terminal 13 Anode terminal 14 Solder 15 Welded portion 16 Resin exterior

Claims (8)

A metal powder dispersion containing a valve action metal powder, a binder resin, and a solvent, wherein the median diameter of the dispersion particles of the valve action metal powder in a particle size distribution on a volume basis is 5 to 100 μm, and the particle size distribution The standard deviation σ obtained by the following formula (1), formula (2), and formula (3) based on the formula (1) is 0.41 or more.

(In the formula, x _j is the j-th value from the smallest when the horizontal axis with a logarithmic scale from 0.08 μm to 3000 μm is equally divided into 50, and q _j is the particle size x _j to x _{j + 1.} (The percentage of the total volume of particles in between the total volume of all particles is expressed as a percentage.)   A metal powder dispersion containing a valve action metal powder, a binder resin, and a solvent, wherein the median diameter of the dispersion particles of the valve action metal powder in a particle size distribution on a volume basis is 10 to 25 μm, and the particle diameter The metal powder dispersion according to claim 1, wherein the content of dispersed particles having a particle size of 3.5 μm or less is 12% by mass or more.   The metal powder dispersion according to claim 1 or 2, which is used for forming an electrolytic capacitor anode element.   The molded object for electrolytic capacitor anode elements obtained by apply | coating or printing the metal powder dispersion liquid of Claim 1 or 2 on a base | substrate, and drying.   5. The electrolytic capacitor anode element molded body according to claim 4 is peeled off from the base, and the electrolytic capacitor anode element molded body peeled off from the base is overlapped and joined with a lead wire made of a valve metal interposed therebetween. An electrolytic capacitor anode element obtained by forming a body and sintering the joined body.   An electrolytic capacitor using the electrolytic capacitor anode element according to claim 5.   The manufacturing method of the molded object for electrolytic capacitor anode elements which apply | coats or prints the metal powder dispersion liquid of Claim 1 or 2 on a base | substrate, and obtains the molded object for electrolytic capacitor anode elements by drying. The molded body for an electrolytic capacitor anode element manufactured by the manufacturing method according to claim 7 is peeled from the base, and the molded body for the electrolytic capacitor anode element peeled from the base is sandwiched between lead wires made of a valve metal. A method for producing an electrolytic capacitor anode element, wherein a joined body is formed by sandwiching and overlapping, and the joined body is sintered to obtain an electrolytic capacitor anode element.

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