JP2008277811A - 複数の薄い粉末形成アノードを含む湿式電解キャパシタ - Google Patents
複数の薄い粉末形成アノードを含む湿式電解キャパシタ Download PDFInfo
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- JP2008277811A JP2008277811A JP2008107277A JP2008107277A JP2008277811A JP 2008277811 A JP2008277811 A JP 2008277811A JP 2008107277 A JP2008107277 A JP 2008107277A JP 2008107277 A JP2008107277 A JP 2008107277A JP 2008277811 A JP2008277811 A JP 2008277811A
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- Prior art keywords
- anode
- cathode
- electrolytic capacitor
- wet electrolytic
- acid
- Prior art date
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Abstract
【解決手段】複数の薄い粉末形成アノードと、カソード及びこれらアノード及び電流収集器に電気的に接触して配置された作用電解質で湿式電解キャパシタを構成し、かつ、アノードの個数を、2ないし40個、アノードの厚みを約1500マイクロメーター以下とする。
【選択図】図2
Description
当業者に向けられた最良の態様を含む本発明の完全な開示を、添付図面を参照して以下に詳細に行なう。
本発明の同じ又は同様の特徴又は要素を表わすために明細書及び添付図面では参照文字を繰り返し使用する。
アノードは、一般的に、バルブ金属(即ち、酸化し得る金属)により主として構成された粉末組成物から形成されるか、又はバルブ金属を一成分として含む化合物から形成される。使用することのできる適当なバルブ金属は、タンタル、ニオブ、アルミニウム、ハフニウム、チタン、これら金属の合金、等を含むが、これらに限定されない。例えば、アノードは、一般的に半導体又は高伝導性材料と考えられるバルブ金属酸化物又は窒化物(例えば、酸化ニオブ、酸化タンタル、窒化タンタル、窒化にオブ、等)から作ることができる。アノードに使用するのに特に適したバルブ金属酸化物は、ニオブ対酸素の原子比が1:2.5未満、ある実施形態では、1:1.5未満、又、ある実施形態では、1:1.1未満、又、ある実施形態では、1:1.0±0.2である酸化ニオブを含む。例えば、酸化ニオブは、Nb0.7、NbO1.0、NbO1.1、及びNbO2である。このようなバルブ金属酸化物の付加的な例が、全ての目的で参考としてここに援用するFife氏の米国特許第6,322,912号に説明されている。又、バルブ金属窒化物の例は、T.Tripp著の“Tantalum Nitride: A New Substrate for Solid Electrolytic Capacitors”; Proceedings of CARTS 2000: 20th Capacitor and Resistor Technology Symposium, 6-20, March 2000、に説明されている。
カソードは、種々の技術のいずれかを使用して構成することができる。一実施形態では、カソードは、キャパシタの形成に使用するのに適した金属、例えば、タンタル、ニオブ、アルミニウム、ニッケル、ハフニウム、チタン、銅、銀、スチール(例えば、ステンレス)、その合金、等で形成された電流収集器を含む。カソードの電流収集器の構成は、当業者によく知られたように、一般的に変化し得る。例えば、電流収集器は、容器、カン、ホイル、シート、発泡材、メッシュ、スクリーン、布、フェルト、等の形態でよい。一実施形態では、カソードの電流収集器は、メッシュ材料である。カソードの電流収集器の表面積は、あるレベルのキャパシタンスを与えるように選択される。例えば、カソードの電流収集器は、約0.1ないし約25平方センチメーター、ある実施形態では、約0.2ないし約15平方センチメーター、又、ある実施形態では、約0.5ないし約10平方センチメーターの表面積をカバーする。電流収集器の比表面積は、この範囲より相当に大きくてもよいことを理解されたい。
作用電解質は、アノードとカソードとの間に接続路を形成する電気的に活性な材料で、一般的に、溶液(例えば、水性又は非水性)、分散体、ゲル、等の液体の形態である。例えば、作用電解質は、酸(例えば、硫酸、燐酸、又は硝酸)、塩基(例えば、水酸化カリウム)、又は塩(例えば、硝酸塩のようなアンモニウム塩)の水溶液、並びにこの技術で知られた他の適当な作用電解質、例えば、有機溶媒に塩を分解したもの(例えば、グリコール系溶液にアンモニウム塩を分解したもの)である。種々の他の電解質が、全ての目的で参考としてここに援用するEvans氏等の米国特許第5,369,547号及び第6,594,140号に説明されている。
上述したものに加えて、湿式電解キャパシタには、他の任意の成分を使用することもできる。例えば、電流収集器及び/又はカソード被覆の上に横たわる導電性ポリマー被覆を使用することができる。適当な導電性ポリマーは、ポリピロル;ポリシオフェン、例えば、ポリ(3,4−エチレンジオキシチオフェン)(PEDT);ポリアニリン;ポリアセチレン;ポリ−p−フェニレン;及びその派生物を含むが、これらに限定されない。又、導電性ポリマー被覆は、複数の導電性ポリマー層から形成されてもよい。例えば、導電性ポリマー被覆は、PEDTから形成された1つの層と、ポリピロルから形成された別の層を含んでもよい。
最初に次の組成からセラミック本体が形成された。
材料 Wt%
脱イオン水 19.05
非イオン性表面活性剤 0.19
非イオン性ポリマー分散剤 1.30
アクリル系バインダー 9.76
Nb2O5粉末 69.70
例1のセラミック本体から湿式電解キャパシタが形成された。最初に、ステンレススチールメッシュ(McMasterから入手した150x150メッシュ)を、2.2cmx1.1cmの長方形にカットした。カソードリード線(アニールされたステンレススチール304ワイヤ、150μmのゲージ)を、2.5cmの長さに切断した。次いで、これら長方形及びリード線を、最初に、超音波バスにおいて45℃の石鹸水で30分間洗浄し、次いで、脱イオン(DI)水で4回すすいだ。85℃のオーブンで30分間乾燥した後に、サンプルを周囲温度においてアセトンで20分間脱脂した。サンプルを85℃のオーブンで乾燥して、全ての残留アセトンを除去し、DI水で5回すすぎ、次いで、85℃のオーブンで乾燥した。カソードリード線を、スポット溶接機を使用して長方形メッシュの1.1cm辺の中間に溶接した。深さは、約1.0mmであった。次いで、長方形メッシュを、1.0vol%のH2SO4及び0.1vol%のHClにおいて1分間エッチングし、DI水で45回脱脂し、そして周囲温度において送風機で乾燥した。それにより得られたメッシュ基板の厚みは、約130μmであった。
テーブル1.作用電解質の組成及び特性
但し、C:キャパシタンス(F)
f:周波数(Hz)
Z”:インピーダンスの虚数部(Ω)
但し、C:カソードキャパシタンス
Q:電荷
U:カソード電位
例2で述べたようにキャパシタを形成したが、カソードインクにカーボンブラックを使用しなかった。それにより得られるカソード荷重は、0.0107グラムであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.57mF、2.42mF及び2.37mFであった。1000Hzの周波数におけるESRは、1.98Ωであった。カソードキャパシタンスは、550.0mFと推定された。
例2で述べたようにキャパシタを形成したが、1.0グラムのTorlon TF4000を添加した。カソード荷重は、0.0113グラムであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.54mF、2.41mF及び2.35mFであった。1000Hzの周波数におけるESRは、1.35Ωであった。カソードキャパシタンスは、550.0mFと推定された。
例2で述べたようにキャパシタを形成したが、0.4グラムのアセチレンカーボン(Chevron)を導電性フィラーとして使用した。カソード荷重は、0.0060グラムであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.60mF、2.36mF及び2.23mFであった。1000Hzの周波数におけるESRは、1.15Ωであった。カソードキャパシタンスは、500.0mFと推定された。
例5で述べたようにキャパシタを形成したが、ステンレススチールメッシュは、SS Monel 304 120x120メッシュであった。カソード荷重は、0.0074グラムであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.64mF、2.46mF及び2.39mFであった。1000Hzの周波数におけるESRは、1.24Ωであった。カソードキャパシタンスは、403.4mFと推定された。
例6で述べたようにキャパシタを形成したが、ステンレススチールメッシュは、SS Monel 316 150x150メッシュであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.69mF、2.47mF及び2.37mFであった。1000Hzの周波数におけるESRは、1.24Ωであった。カソードキャパシタンスは、384.9mFと推定された。
例5で述べたようにキャパシタを形成したが、カソード基板は、110 PPI(Inco)のニッケル発泡体であった。カソード荷重は、0.013グラムであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.66mF、2.37mF及び2.28mFであった。1000Hzの周波数におけるESRは、1.13Ωであった。カソードキャパシタンスは、1250mFと推定された。
例7で述べたようにキャパシタを形成したが、0.4グラムのBP2000カーボンブラックを導電性フィラーとして使用した。カソード荷重は、0.0074グラムであった。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、2.54mF、2.38mF及び2.32mFであった。1000Hzの周波数におけるESRは、1.16Ωであった。カソードキャパシタンスは、372.3mFと推定された。
10片のNbOアノードと、11片のカソードと、20片のセパレータペーパーを例2で説明したように準備し、カソード、セパレータ及びアノードの順に積み重ねた。各長方形アノードは、長さが11.0mmで、巾が11.0mmで、厚みが0.7mmであった。アノードのサイズに一致させるために、カソードも、11.0mm巾の方形にカットした。例2の同じサイズのセパレータペーパーを単にU字形状に折り返し、アノード片を包んだ。アノードリード線及びカソードリード線をスタックから互いに逆方向に取り出した。スタック全体を1片のScotchテープで巻いた。アノードのタンタル及びカソードのステンレススチールリード線を全て6.0mmの長さに切断した。アノードリード線を、直径0.2mmの1本の重ゲージのステンレススチールワイヤに溶接し、そしてカソードのリード線を別のワイヤに溶接した。スタックの厚みは、10.0mmであった。アノード/セパレータ/カソードアッセンブリを、例2で使用した水性電解質において、30分間、真空含浸した。0.1Hzにおいて測定したキャパシタンスは、2.0V、5.0V及び8.0Vのバイアスに対して、各々、14.53mF、12.84mF及び12.34mFであった。1000Hzの周波数におけるESRは、0.22Ωであった。
寸法を若干変更して例2で述べたようにアノード及びカソードを準備した。より詳細には、アノード及びカソード基板を、巾が1.0cmの方形にカットした。例2と同じサイズのセパレータペーパーをU字形状に折り返してアノードを包んだ。2つのNbOアノードを、3つのカソードと一緒に水平に、図3に示すように積み重ねた。アノードのタンタルリード線及びカソードのステンレススチールリード線を6.0mmの長さに切断した。アノードのタンタルリード線を、直径0.2mmの重ゲージのタンタルワイヤに溶接し、そしてカソードのステンレススチールリード線を、アルゴン雰囲気保護のもとでレーザー溶接機により重ゲージのステンレススチールワイヤに溶接した。両重ゲージワイヤをスポット溶接機でニオブロッドに溶接した。次いで、ニッケルリード線をこれらのニオブロッドに溶接した。このアッセンブリにスコッチテープを巻き圧縮性を増すと共に、作用電解質(以下のテーブル2に示す)において30分間真空願した後に、ケースに挿入した。
アノード及びカソードを、例2に述べたように準備した。アノードを、5.16mmx3.88mmx0.58mmの長方形にスライスした。これらアノードの形成には、2つの異なる形成電解質を使用した。電解質は、1.0wt%のH3PO4(燐酸)及び0.5wt%のH3PO4を0.5wt%のH5PO4(ポリ燐酸)と混合したものであった。これらのアノードは、最初に、24ボルトのもとで85℃において120分間アノード処理された。幾つかのアノードは、後で、真空アニールし、及び/又はテーブル1に示すような第2の形成を行なった。ガルバノスタティックチャージ/ディスチャージ方法を使用して例11で述べたように電解質Bにおける大きなTaスラグカソードに対してこれらアノードのDCセルキャパシタンスを測定することによりキャパシタンスを決定した。1.0wt%のH3PO4に基づいて漏れ電流を測定した。2.0ボルトのバイアスにおけるDCキャパシタンス、及び16ボルトの定格電圧を印加した2時間後に測定した漏れ電流を、85℃における正規化した漏れ電流の計算に使用した。その結果をテーブル4に示す。
テーブル4.アノード処理及び/又は真空アニールの条件及び結果
例1の方法を使用して本体を形成したが、8層の2つのスタックを使用した。パッドから部分を刻んだ。130の部分の平均を使用して次のグリーン寸法を測定した。
長さ: 5.51 mm (std 0.041)
巾: 3.85 mm (std 0.104)
厚み: 0.598 mm (std 0.0128)
重量: 0.0357 g (std 0.0012)
密度 (平均から計算): 2.815 g/cc (std 0.077)
長さ: 5.18 mm (std 0.054)
巾: 3.62 mm (std 0.082)
厚み: 0.550 mm (std 0.0100)
重量: 0.0268 g (std 0.0007)
密度 (平均から計算): 2.603 g/cc (std 0.072)
例14の方法を使用して本体を形成したが、ナイロンリボン(寸法0.6858mmx0.0762mm)を使用して犠牲スロットを形成した。
例15の方法を使用して本体を形成したが、取り付け及び積層の前に、先鋭なニードルを使用して各テープに穴を開けた。これは、最終的な製品に多孔性を生じさせるために行なわれた。
例16の方法を使用して本体を形成したが、取り付け及び積層の前に有機インクの線を各テープの面に印刷した。インクは、次の組成から作られた。
材料 量(グラム)
Reuscheオイル、形式G-2622 8.266
Nb2O5 粉末 2.135
カーボンブラック、Columbian Raven 22 2.923
粉末の組成は、最初、次のように形成した。
材料 Wt%
DI水 16.54
非イオン性表面活性剤 0.23
アニオンポリマー分散剤 0.35
アクリル系バインダー 8.01
Nb2O5 粉末 71.07
多層のNbO本体を、例18に基づいて形成した。それとは別に、Habererアノードプレスを使用して、HC StarckのNbOからのNbO本体を0.19mmのタンタルワイヤにプレスした。この本体を、次いで、1500℃で焼結して、ワイヤ上に濃密な構造体を形成した。次いで、0.5mmスポットのTrumpf Profiweldレーザーを使用して、先に形成した多層本体にこのワイヤのNbO部分を溶接した。これらのアノードは、32Vに到達するまで0.1A/アノードの一定電流を使用して85℃の温度で8600μSの導電率に調整された燐酸バスにおいて32Vにアノード処理された。アノードは、次いで、32Vに90分間保持した。アノード処理された部分のキャパシタンスは、カソードに使用された大きな多孔性タンタル本体と共に18%硫酸中で測定された。キャパシタンスの測定を行うのに使用した計器は、Hewlett Packard4263A LCRメーターであった。キャパシタンスは、10Vの外部バイアスを使用して120Hzで測定された。平均キャパシタンス(8個の部分)は、28.0μFであった。
12:供給ロール
13:担体基板膜
14:液体粉末組成物
15:ドクターブレード
22:ギャップ
24:セラミック層
32:ロール
62:アノードリード
64:カソード
65:アノード
72:カソードリード
100:アレー
117:セパレータ
119:容器
121:頂部
123:底部
125:蓋
144:作用電解質
162:アノード端子
172:カソード端子
200:キャパシタ
Claims (22)
- 厚みが約1500マイクロメーター以下で、粉末から作られた複数のアノードと、
カソードと、
前記カソード及びアノードに電気的に接触して配置された作用電解質と、
前記アノードに電気的に接続されたアノード端子と、
前記カソードに電気的に接続されたカソード端子と、
を備えた湿式電解キャパシタ。 - 前記キャパシタは、2ないし40個のアノードを備えた、請求項1に記載の湿式電解キャパシタ。
- 前記キャパシタは、3ないし30個のアノードを備えた、請求項1に記載の湿式電解キャパシタ。
- 前記アノードは、厚みが約50ないし約500マイクロメーターである、請求項1に記載の湿式電解キャパシタ。
- 前記アノードは、タンタルを含む、請求項1に記載の湿式電解キャパシタ。
- 前記アノードは、酸化ニオブを含む、請求項1に記載の湿式電解キャパシタ。
- 前記アノードは、粉末を化学的に還元することにより形成される、請求項1に記載の湿式電解キャパシタ。
- 前記粉末は、五酸化ニオブを含む、請求項7に記載の湿式電解キャパシタ。
- 前記アノードからアノードリードが延び、このアノードリードは、前記アノード端子に接続される、請求項1に記載の湿式電解キャパシタ。
- 前記カソードからカソードリードが延び、このカソードリードは、前記カソード端子に接続される、請求項1に記載の湿式電解キャパシタ。
- 前記アノードは、誘電体層を含む、請求項1に記載の湿式電解キャパシタ。
- 前記キャパシタは、複数のカソードを備え、少なくとも2つのカソード間に少なくとも1つのアノードが配置される、請求項1に記載の湿式電解キャパシタ。
- 前記キャパシタは、3ないし40個のアノードを備えた、請求項12に記載の湿式電解キャパシタ。
- 前記アノード及びカソードは、垂直方向に整列される、請求項12に記載の湿式電解キャパシタ。
- 前記アノード及びカソードは、水平方向に整列される、請求項12に記載の湿式電解キャパシタ。
- 前記カソードと少なくとも1つのアノードとの間に配置されたセパレータを更に備え、該セパレータは、前記作用電解質の流れを許す、請求項1に記載の湿式電解キャパシタ。
- 前記カソード、アノード及び作用電解質は、容器内に包囲される、請求項1に記載の湿式電解キャパシタ。
- 前記容器は、前記アノード端子及びカソード端子が貫通して延びる蓋を含む、請求項17に記載の湿式電解キャパシタ。
- 前記カソードは、電流収集器と、電気化学的に活性な粒子のコーティングを含む、請求項1に記載の湿式電解キャパシタ。
- 前記作用電解質は、水溶液である、請求項1に記載の湿式電解キャパシタ。
- 前記キャパシタは、1000Hzの周波数において2ボルトバイアス及び1ボルト信号で測定されて、約1500ミリオーム以下の等価直列抵抗を示す、請求項1に記載の湿式電解キャパシタ。
- 前記キャパシタは、1000Hzの周波数において2ボルトバイアス及び1ボルト信号で測定されて、約500ミリオーム以下の等価直列抵抗を示す、請求項1に記載の湿式電解キャパシタ。
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Also Published As
Publication number | Publication date |
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US7649730B2 (en) | 2010-01-19 |
DE102008000329A1 (de) | 2008-09-25 |
US20080232030A1 (en) | 2008-09-25 |
KR20080085757A (ko) | 2008-09-24 |
CN101271768A (zh) | 2008-09-24 |
GB0802511D0 (en) | 2008-03-19 |
GB2448019A (en) | 2008-10-01 |
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