JP5541756B2 - Manufacturing method of solid electrolytic capacitor - Google Patents

Description

  The present invention relates to a method for manufacturing a solid electrolytic capacitor, and more particularly to a method for manufacturing a solid electrolytic capacitor in which the method and conditions for impregnating a capacitor element with a monomer solution and an oxidant solution are improved.

  An electrolytic capacitor using a metal having a valve action such as tantalum or aluminum is obtained by expanding the dielectric by making the valve action metal as the anode-side counter electrode into the shape of a sintered body or an etching foil. Since it is small and a large capacity can be obtained, it is widely used. In particular, a solid electrolytic capacitor using a solid electrolyte as an electrolyte has features such as small size, large capacity, low equivalent series resistance, easy to chip, and suitable for surface mounting. It is indispensable for miniaturization, high functionality and low cost of electronic equipment.

  In this type of solid electrolytic capacitor, as a small-sized and large-capacity application, an anode foil and a cathode foil made of a valve metal such as aluminum are generally wound with a separator interposed therebetween to form a capacitor element. It is impregnated with a driving electrolyte, and has a sealed structure in which a capacitor element is housed in a metal case such as aluminum or a case made of synthetic resin. As the anode material, aluminum, tantalum, niobium, titanium and the like are used, and as the cathode material, the same kind of metal as the anode material is used.

  As solid electrolytes used for solid electrolytic capacitors, manganese dioxide and 7,7,8,8-tetracyanoquinodimethane (TCNQ) complexes are known. There is a technique (Japanese Patent Laid-Open No. 2-15611) that focuses on polyethylenedioxythiophene (hereinafter referred to as PEDT) having excellent adhesion to an oxide film layer of an electrode.

  A solid electrolytic capacitor of a type in which a solid electrolyte layer made of PEDT is formed on such a wound capacitor element is manufactured as follows. First, the surface of the anode foil made of valve action metal such as aluminum is roughened by electrochemical etching treatment in an aqueous chloride solution to form many etching pits, and then in an aqueous solution such as ammonium borate. A voltage is applied to form an oxide film layer serving as a dielectric (chemical conversion). Similar to the anode foil, the cathode foil is made of a valve metal such as aluminum, but the surface is only subjected to etching treatment.

  Thus, the anode foil having the oxide film layer formed on the surface and the cathode foil having only the etching pits are wound through a separator to form a capacitor element. Subsequently, 3,4-ethylenedioxythiophene (hereinafter referred to as EDT) and an oxidant solution are respectively discharged onto the capacitor element that has undergone restoration conversion to promote the EDT polymerization reaction in the capacitor element, and PEDT. A solid electrolyte layer is produced.

JP 2000-195758 A JP 2000-114118 A

  However, when a solid electrolytic capacitor was manufactured in an actual mass production process using the above manufacturing method, there was a problem that initial characteristics, reflow characteristics, and reliability after reflow varied. That is, if the solid electrolytic capacitor obtained by the conventional manufacturing method as described above is used as a horizontal or vertical surface mounting chip component and subjected to high-temperature reflow soldering, the capacitance decreases during reflow soldering and leakage occurs. There was a problem that the current increased.

  In particular, high melting point lead-free solder has recently been used due to environmental problems, and the solder reflow temperature has further increased from 200 to 220 ° C. to 230 to 270 ° C. Therefore, high temperature reflow soldering was performed. Even in such cases, there has been a strong demand for the development of a solid electrolytic capacitor in which the metal case and sealing rubber do not swell and the characteristics are not deteriorated. Such a problem occurs not only when EDT is used as the polymerizable monomer but also when other thiophene derivatives, pyrrole, aniline, and the like are used.

  The present invention has been proposed in order to solve the above-described problems of the prior art, and its object is to provide a solid electrolytic capacitor excellent in initial characteristics, reflow characteristics, and reliability after reflow in a mass production process. The object of the present invention is to provide a method of manufacturing a solid electrolytic capacitor capable of obtaining the above.

In the present invention, a solid electrolyte layer made of a conductive polymer is formed by impregnating a polymerizable monomer and an oxidizing agent on a capacitor element in which an anode electrode foil and a cathode electrode foil are wound with a separator interposed therebetween. In the method for producing a solid electrolytic capacitor stored in a capacitor, the capacitor element formed with the conductive polymer is dried, so that the moisture content of the capacitor element before storing in a predetermined case is 6.3φ or more and less than 8φ, 6L or more. It is characterized by being prepared to 1.0 mg / element or less in a range of less than 7 L.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of a solid electrolytic capacitor and a solid electrolytic capacitor which can obtain the solid electrolytic capacitor excellent in the initial characteristic, the reflow characteristic, and the reliability after reflow in a mass production process can be provided.

  As a result of intensive studies to solve the above-mentioned problems, the inventors have stored the capacitor element in the outer case in the final process, and when the opening end is sealed with rubber by crimping, It was found that the amount of moisture is a factor that greatly affects the reflow characteristics, and various studies were made on the amount of moisture in the capacitor element before caulking.

(Moisture content of capacitor element before caulking)
The inventors of the present invention have adsorbed moisture to a once dried capacitor element and examined its characteristics. As a result, it has been found that the smaller the amount of moisture, the better the initial characteristics, reflow characteristics, and reliability after reflow. Next, when a plurality of capacitor elements having different sizes in the range of 6.3 to 10φ and 6 to 8L were examined by changing the amount of moisture to be adsorbed, the moisture amount was a constant value in any size. Lesser results have been obtained.

  This is because by reducing the amount of moisture below a certain value, the evaporation of moisture due to heat during reflow can be reduced, so that the interface state between the dielectric oxide film and PEDT deteriorates due to the evaporation of moisture. This is thought to be because the decrease in electrostatic capacity and the increase in ESR could be prevented.

  In addition, after forming PEDT, sealing and aging are performed. However, if the moisture contained in the capacitor element is large, the moisture influences during aging and the interface state between the dielectric oxide film and PEDT becomes worse. Although it causes a decrease in capacity and an increase in ESR, it is considered that a decrease in capacitance and an increase in ESR could be prevented by reducing the amount of water. The moisture content is preferably 1.0 mg / element or less, more preferably 0.7 mg / element or less. Moreover, in order to adjust to this moisture content, a normal drying method can be used. That is, a method of holding at a temperature of 100 ° C. or higher for a certain time can be used.

(Method for manufacturing solid electrolytic capacitor)
The anode foil is wound together with the cathode foil and the separator to form a capacitor element. On the other hand, a polymerizable monomer, an oxidant, and a predetermined solvent are mixed in a predetermined container, and the capacitor element is immersed in the mixed solution to cause a polymerization reaction of the conductive polymer in the capacitor element, thereby producing a solid electrolyte layer. Form. Thereafter, the capacitor element is dried at 60 to 120 ° C. for 10 to 60 minutes to prepare a capacitor element having a moisture content of 1.0 mg / element or less, and the capacitor element is housed in a bottomed cylindrical case. Then, the opening is sealed with rubber, and aging is performed to complete the solid electrolytic capacitor.

(EDT and oxidizing agent)
When EDT is used as the polymerizable monomer, EDT monomer can be used as EDT impregnated in the capacitor element, but a monomer solution in which EDT and a volatile solvent are mixed at a volume ratio of 1: 0 to 1: 3. Can also be used. Examples of the volatile solvent include hydrocarbons such as pentane, ethers such as tetrahydrofuran, esters such as ethyl formate, ketones such as acetone, alcohols such as methanol, nitrogen compounds such as acetonitrile, and the like. Of these, methanol, ethanol, acetone and the like are preferable. As the oxidizing agent, an aqueous solution of ferric paratoluenesulfonate, periodic acid or iodic acid dissolved in butanol can be used, and the concentration of the oxidizing agent with respect to the solvent is preferably 40 to 55 wt%.

(Mixing ratio of EDT and oxidizing agent)
The mixing ratio of EDT and oxidizing agent (without solvent) is preferably in the range of 1: 0.9 to 1: 2.2 by weight, and in the range of 1: 1.3 to 1: 2.0. More preferred. Outside this range, ESR increases. The reason is considered as follows. That is, when the amount of the oxidizing agent relative to the monomer is too large, the amount of the monomer to be impregnated relatively decreases, so that the amount of PEDT formed decreases and the ESR increases. On the other hand, when the amount of the oxidizing agent is too small, the oxidizing agent necessary for polymerizing the monomer is insufficient, the amount of PEDT formed is lowered, and the ESR is increased.

(Immersion time)
The time for immersing the capacitor element in the mixed solution is determined depending on the size of the capacitor element, but it is preferably 5 seconds or more for a capacitor element of about φ5 × 2L, 10 seconds or more for a capacitor element of about φ8 × 4L, and at least 5 seconds. Must be immersed. In addition, even if it is immersed for a long time, there is no harmful effect on the characteristics.

(Chemical solution for restoration conversion)
As the chemical solution for restoration chemical conversion, phosphoric acid type chemicals such as ammonium dihydrogen phosphate and diammonium hydrogen phosphate, boric acid type chemicals such as ammonium borate, and adipic acid type chemicals such as ammonium adipate, etc. Although a liquid can be used, it is preferable to use ammonium dihydrogen phosphate. The immersion time is preferably 5 to 120 minutes.

(Other polymerizable monomers)
As the polymerizable monomer used in the present invention, in addition to the above EDT, a thiophene derivative other than EDT, aniline, pyrrole, furan, acetylene or a derivative thereof, which is oxidatively polymerized with a predetermined oxidizing agent, is a conductive polymer. As long as it forms, it can be applied. As the thiophene derivative, one having the following structural formula can be used.

(Action / Effect)
As described above, the moisture content of the capacitor element before storing the capacitor element formed with the conductive polymer in the outer case is set to 1.0 mg / element or less, thereby reducing moisture vaporization due to heat during reflow. Therefore, it is possible to prevent a decrease in capacitance and an increase in ESR caused by the deterioration of the interface state between the dielectric oxide film and PEDT due to vaporization of moisture.

  Also, by reducing the amount of moisture, it is possible to prevent the interface state between the dielectric oxide film and PEDT from becoming worse during aging due to the influence of moisture, thereby causing a decrease in capacitance and an increase in ESR. A solid electrolytic capacitor having good characteristics can be obtained.

  Subsequently, the present invention will be described in more detail based on Examples and Comparative Examples manufactured as follows. In Examples 1 to 3 and Comparative Example 1 belonging to Group A, the shape of the capacitor element is 6.3φ × 6 L, the rated voltage is 16 WV, the rated capacity is 39 μF, and Examples 4 to 5 belonging to Group B are Comparative Example 2 has a capacitor element shape of 8φ × 7 L, a rated voltage of 16 WV, and a rated capacity of 82 μF. Examples 6 to 7 and Comparative Example 3 belonging to Group C have a capacitor element shape of 10φ × 8 L, The rated voltage is 16 WV and the rated capacity is 180 μF.

(Examples 1-3)
An electrode drawing means was connected to the anode foil and the cathode foil each having an oxide film layer formed on the surface, and both electrode foils were wound through a separator to form a capacitor element having an element shape of 6.3φ × 6L. Then, after this capacitor element was immersed in an aqueous solution of ammonium dihydrogen phosphate for 40 minutes for restoration conversion, drying was performed at 100 ° C. for 10 minutes. On the other hand, a butanol solution of EDT and 45% ferric paratoluenesulfonic acid was poured into a cup-shaped container so that the weight ratio would be 1: 0.8 to prepare a mixed solution. And the capacitor | condenser element was immersed in the said liquid mixture for 10 second, and it heated at 120 degreeC for 1 hour, the polymerization reaction of PEDT was generated within the capacitor | condenser element, and the solid electrolyte layer was formed.

Then, this capacitor | condenser element was dried at 100 degreeC for 30 minute (s), and the moisture content of the capacitor | condenser element was adjusted to 0.5, 0.7, and 1.0 mg / element, respectively. Then, this capacitor element was inserted into a bottomed cylindrical aluminum case, and the opening was rubber-sealed by drawing to perform aging, thereby producing a solid electrolytic capacitor. These solid electrolytic capacitors have a rated voltage of 16 WV and a rated capacity of 39 μF.
(Comparative Example 1)
Solid electrolytic capacitors were prepared in the same manner as in Examples 1 to 3 except that the moisture content of the capacitor element was 1.5 mg / element.

(Examples 4 to 5)
A solid electrolytic capacitor was prepared in the same manner as in Examples 1 to 3 except that the element shape was 8φ × 7L. The rated voltage is 16 WV and the rated capacity is 82 μF.
(Comparative Example 2)
Solid electrolytic capacitors were prepared in the same manner as in Examples 4 to 5 except that the moisture content of the capacitor element was 1.5 mg / element.

(Examples 6 to 7)
Solid electrolytic capacitors were prepared in the same manner as in Examples 1 to 3 except that the element shape was 10φ × 8L. The rated voltage is 16 WV and the rated capacity is 180 μF.
(Comparative Example 3)
Solid electrolytic capacitors were prepared in the same manner as in Examples 6 to 7 except that the moisture content of the capacitor element was 1.5 mg / element.

[Comparison result]
About each solid electrolytic capacitor of Examples 1-7 obtained by said method and Comparative Examples 1-3, when the initial characteristic, the reflow characteristic, and the surge test after reflow were done, the result as shown in Table 1 was obtained. Obtained. The reflow test conditions were a peak temperature of 250 ° C. and a hold of 230 ° C. or more for 30 seconds, and the surge test conditions were a charge / discharge of a surge voltage of 18.4 V 1000 times at 125 ° C. after the reflow test described above. Is.

  As is apparent from Table 1, in each of the groups A to C having different capacitor element sizes, each of the examples in which the moisture content of the capacitor element is 0.5 to 1.0 mg / element has a moisture content of 1.5 mg. / Compared to each comparative example of the element, good and stable characteristics were obtained for the initial characteristics, reflow characteristics, and surge test after reflow. From this, it was shown that a solid electrolytic capacitor having good characteristics can be obtained by setting the moisture content of the capacitor element to 1.0 mg / element or less.

  In Group A, it was found that even better characteristics were obtained in Examples 1 and 2 where the moisture content of the capacitor element was 0.5 to 0.7 mg / element. From this, it was shown that when the moisture content of the capacitor element is 0.7 mg / element or less, a solid electrolytic capacitor having even better characteristics can be obtained.

Claims (3)

A solid electrolyte layer formed by impregnating a polymerizable monomer and an oxidant into a capacitor element in which an anode electrode foil and a cathode electrode foil are wound via a separator to form a solid electrolyte layer made of a conductive polymer and accommodated in a predetermined case In the method of manufacturing an electrolytic capacitor,
By drying the capacitor element on which the conductive polymer is formed, the moisture content of the capacitor element before being stored in a predetermined case is 1.0 mg / element in a range of 6.3φ to less than 8φ, and 6L to less than 7L. A method for producing a solid electrolytic capacitor, which is prepared as follows.   The method for producing a solid electrolytic capacitor according to claim 1, wherein the polymerizable monomer is a thiophene derivative.   The method for producing a solid electrolytic capacitor according to claim 2, wherein the thiophene derivative is 3,4-ethylenedioxythiophene.