WO2013179996A1 - 固体電解コンデンサ素子の製造方法 - Google Patents
固体電解コンデンサ素子の製造方法 Download PDFInfo
- Publication number
- WO2013179996A1 WO2013179996A1 PCT/JP2013/064317 JP2013064317W WO2013179996A1 WO 2013179996 A1 WO2013179996 A1 WO 2013179996A1 JP 2013064317 W JP2013064317 W JP 2013064317W WO 2013179996 A1 WO2013179996 A1 WO 2013179996A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- capacitor element
- carbon
- layer
- tungsten
- chemical conversion
- Prior art date
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- 239000003990 capacitor Substances 0.000 title claims abstract description 70
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 25
- 238000000034 method Methods 0.000 title claims abstract description 23
- 239000007787 solid Substances 0.000 title claims abstract description 21
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 73
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 73
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims abstract description 59
- 229920005989 resin Polymers 0.000 claims abstract description 34
- 239000011347 resin Substances 0.000 claims abstract description 34
- 230000008439 repair process Effects 0.000 claims abstract description 29
- 229910052721 tungsten Inorganic materials 0.000 claims abstract description 29
- 239000010937 tungsten Substances 0.000 claims abstract description 29
- 239000002245 particle Substances 0.000 claims abstract description 26
- 239000004065 semiconductor Substances 0.000 claims abstract description 17
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052709 silver Inorganic materials 0.000 claims abstract description 13
- 239000004332 silver Substances 0.000 claims abstract description 13
- 238000010030 laminating Methods 0.000 claims abstract description 4
- 238000006243 chemical reaction Methods 0.000 claims description 61
- 239000000126 substance Substances 0.000 claims description 43
- 239000007864 aqueous solution Substances 0.000 claims description 8
- -1 carboxyvinyl Chemical group 0.000 claims description 8
- 239000000758 substrate Substances 0.000 claims description 6
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 claims description 4
- 239000004925 Acrylic resin Substances 0.000 claims description 3
- 229920000178 Acrylic resin Polymers 0.000 claims description 3
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 claims description 3
- 229920000180 alkyd Polymers 0.000 claims description 3
- 239000005011 phenolic resin Substances 0.000 claims description 3
- 239000000463 material Substances 0.000 abstract description 11
- 230000015572 biosynthetic process Effects 0.000 abstract description 9
- 239000010410 layer Substances 0.000 description 67
- 239000000843 powder Substances 0.000 description 31
- 239000007788 liquid Substances 0.000 description 17
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 12
- 239000000243 solution Substances 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 8
- 238000005121 nitriding Methods 0.000 description 8
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 6
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 5
- 229910052796 boron Inorganic materials 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 239000001257 hydrogen Substances 0.000 description 5
- 229910052739 hydrogen Inorganic materials 0.000 description 5
- 229910052757 nitrogen Inorganic materials 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 4
- 238000003763 carbonization Methods 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 4
- 239000012298 atmosphere Substances 0.000 description 3
- 239000006229 carbon black Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 239000008187 granular material Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- QGLKJKCYBOYXKC-UHFFFAOYSA-N nonaoxidotritungsten Chemical compound O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1 QGLKJKCYBOYXKC-UHFFFAOYSA-N 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 239000011164 primary particle Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 239000005871 repellent Substances 0.000 description 3
- 239000011863 silicon-based powder Substances 0.000 description 3
- 229910052715 tantalum Inorganic materials 0.000 description 3
- WQJQOUPTWCFRMM-UHFFFAOYSA-N tungsten disilicide Chemical compound [Si]#[W]#[Si] WQJQOUPTWCFRMM-UHFFFAOYSA-N 0.000 description 3
- 229910001930 tungsten oxide Inorganic materials 0.000 description 3
- 229910021342 tungsten silicide Inorganic materials 0.000 description 3
- OFEAOSSMQHGXMM-UHFFFAOYSA-N 12007-10-2 Chemical compound [W].[W]=[B] OFEAOSSMQHGXMM-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000003795 desorption Methods 0.000 description 2
- 229910001873 dinitrogen Inorganic materials 0.000 description 2
- 239000003792 electrolyte Substances 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 229910021382 natural graphite Inorganic materials 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- ZNOKGRXACCSDPY-UHFFFAOYSA-N tungsten trioxide Chemical compound O=[W](=O)=O ZNOKGRXACCSDPY-UHFFFAOYSA-N 0.000 description 2
- YMMGRPLNZPTZBS-UHFFFAOYSA-N 2,3-dihydrothieno[2,3-b][1,4]dioxine Chemical compound O1CCOC2=C1C=CS2 YMMGRPLNZPTZBS-UHFFFAOYSA-N 0.000 description 1
- SLXXDIZSDXAXMI-UHFFFAOYSA-N 2,3-dihydrothieno[2,3-b][1,4]dioxine;ethanol Chemical compound CCO.O1CCOC2=C1C=CS2 SLXXDIZSDXAXMI-UHFFFAOYSA-N 0.000 description 1
- JAJIPIAHCFBEPI-UHFFFAOYSA-N 9,10-dioxoanthracene-1-sulfonic acid Chemical compound O=C1C2=CC=CC=C2C(=O)C2=C1C=CC=C2S(=O)(=O)O JAJIPIAHCFBEPI-UHFFFAOYSA-N 0.000 description 1
- 238000004438 BET method Methods 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- AMQJEAYHLZJPGS-UHFFFAOYSA-N N-Pentanol Chemical compound CCCCCO AMQJEAYHLZJPGS-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910001080 W alloy Inorganic materials 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 150000001721 carbon Chemical class 0.000 description 1
- 238000010000 carbonizing Methods 0.000 description 1
- 229920001940 conductive polymer Polymers 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000006837 decompression Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000008151 electrolyte solution Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000012046 mixed solvent Substances 0.000 description 1
- 239000002071 nanotube Substances 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/0029—Processes of manufacture
- H01G9/0036—Formation of the solid electrolyte layer
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/0029—Processes of manufacture
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G9/04—Electrodes or formation of dielectric layers thereon
- H01G9/042—Electrodes or formation of dielectric layers thereon characterised by the material
- H01G9/0425—Electrodes or formation of dielectric layers thereon characterised by the material specially adapted for cathode
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-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
- H01G9/04—Electrodes or formation of dielectric layers thereon
- H01G9/048—Electrodes or formation of dielectric layers thereon characterised by their structure
- H01G9/052—Sintered electrodes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/0029—Processes of manufacture
- H01G9/0032—Processes of manufacture formation of the dielectric layer
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/15—Solid electrolytic capacitors
Definitions
- the present invention relates to a method for producing a solid electrolytic capacitor element having a tungsten base material as an anode body.
- Electrolytic capacitors As the shape of electronic devices such as mobile phones and personal computers becomes smaller, faster, and lighter, capacitors used in these electronic devices are required to be smaller and lighter, with larger capacity and lower ESR. Yes.
- Electrolytic capacitors have been proposed. Electrolytic capacitors that use tungsten as the valve metal and have a sintered body of tungsten powder as the anode body have the same volume of anode body using tantalum powder of the same particle size, compared to electrolytic capacitors that can be obtained with the same conversion voltage.
- Patent Document 2 Japanese Patent Laid-Open No. 2003-272959 discloses a capacitor using a tungsten foil electrode on which a dielectric layer selected from WO 3 , W 2 N, and WN 2 is formed. This is not a solution for the leakage current.
- Patent Document 3 International Publication No. 2004/055843 pamphlet (US Pat. No. 7,154,743) discloses an electrolytic capacitor using an anode selected from tantalum, niobium, titanium, and tungsten. There is no description of specific examples using tungsten in the specification.
- An object of the present invention is to solve the problem of leakage current (LC) in a solid electrolytic capacitor based on tungsten and to provide a tungsten solid electrolytic capacitor that can be put to practical use.
- LC leakage current
- the present inventors have studied in detail a method for manufacturing a solid electrolytic capacitor element in which a dielectric layer, a semiconductor layer, a carbon layer, and a silver layer are sequentially formed on a sintered body of tungsten powder.
- solid electrolytic capacitors based on tantalum or aluminum in general, by forming a semiconductor layer and then carrying out restoration conversion in an aqueous chemical solution, a stable capacitor element without leakage current is formed, and a carbon layer is formed to form a silver layer.
- no chemical conversion (repair formation) is carried out in a chemical conversion liquid containing water as a main component, but the present inventor formed a carbon layer for a solid electrolytic capacitor based on tungsten.
- the present invention has been completed by finding that the leakage current characteristic of the capacitor element produced is improved when restoration conversion is performed in an aqueous chemical solution before forming the silver layer.
- the present invention relates to the following capacitor element manufacturing methods [1] to [7].
- the formation of the carbon layer includes laminating a carbon paste on the semiconductor layer.
- the carbon paste is a resin aqueous solution containing carbon particles, and a repair conversion treatment is performed after the carbon layer is formed and before the silver layer is formed.
- an electrolytic capacitor when an electrolytic capacitor is produced using a capacitor element having a tungsten substrate as an anode body obtained by a manufacturing method in which restoration conversion is performed after forming a carbon layer, a capacitor with a small leakage current can be obtained.
- the yield of good quality products can be increased.
- a sintered body of tungsten powder as a base material (anode body).
- Tungsten powder as a raw material for the base material is commercially available, but tungsten powder with a smaller particle size that is more preferable as the raw material for the base material can be obtained, for example, by pulverizing tungsten trioxide powder in a hydrogen atmosphere.
- An acid and a salt thereof (such as ammonium tungstate) or tungsten halide can be obtained by using a reducing agent such as hydrogen or sodium and appropriately selecting the reducing conditions.
- tungsten powder prepared by using ammonium tungstate as a raw material and appropriately selecting the reducing conditions using a reducing agent can be easily produced from the same raw material with a smaller average particle size of 0.7 ⁇ m. it can.
- tungsten powder having an average particle diameter of 1 ⁇ m obtained by hydrogen reduction of tungsten oxide it is preferable because a capacitor having a higher capacity can be produced.
- the tungsten powder as the raw material of the base material may be granulated (hereinafter, the granulated tungsten powder may be simply referred to as “granulated powder”. Sometimes called "primary powder.") Granulated powder is preferable because it has good fluidity and is easy to perform operations such as molding.
- the granulated powder may further have a pore distribution adjusted by a method similar to that disclosed in, for example, JP 2003-213302 A (European Patent No. 1388870) for niobium powder.
- the granulated powder can be obtained by adding at least one kind of liquid such as water or liquid resin to the primary powder to form granules of an appropriate size, and then heating and sintering under reduced pressure.
- Depressurization conditions for example, 10 kPa or less in a non-oxidizing gas atmosphere such as hydrogen
- high-temperature standing conditions for example, 1100 to 2600 ° C., 0.1 to 100 hours
- Such granulated powder can be classified by sieving to make the particle size uniform. If the volume average particle size is preferably in the range of 50 to 200 ⁇ m, more preferably 100 to 200 ⁇ m, it is advantageous for smooth flow from the hopper of the molding machine to the mold.
- the volume average primary particle size of the primary powder be in the range of 0.1 to 1 ⁇ m, preferably 0.1 to 0.3 ⁇ m, because the capacity of the electrolytic capacitor made from the granulated powder can be particularly increased.
- the specific surface area (by the BET method) of the granulated powder is preferably 0.2 to 20 m 2 / g, more preferably 1.
- the capacity of the electrolytic capacitor can be increased, which is preferable.
- tungsten powder as a raw material for the base material, a powder having at least one selected from tungsten silicide, tungsten nitride, tungsten carbide, and tungsten boride in a part of the surface is also preferably used.
- silicon powder can be mixed well with tungsten powder and heated under reduced pressure to cause a reaction.
- the silicon powder reacts from the surface of the tungsten particles, and tungsten silicide such as W 5 Si 3 is formed in a localized manner within 50 nm from the particle surface layer.
- tungsten silicide such as W 5 Si 3 is formed in a localized manner within 50 nm from the particle surface layer.
- the central part of the primary particles remains as a metal having high conductivity, and when the anode body of a capacitor is manufactured, the equivalent series resistance of the anode body can be kept low, which is preferable.
- the content of tungsten silicide can be adjusted by the amount of silicon added.
- the silicon content of the tungsten powder is preferably 7% by mass or less, more preferably 0.05 to 7% by mass, and particularly preferably 0.2 to 4% by mass.
- a tungsten powder having a silicon content in this range gives a capacitor having good LC characteristics, and is preferable as a powder for an electrolytic capacitor.
- the oxygen content can be suppressed to about 0.05 to 8% by mass.
- the reaction temperature is preferably 1100 ° C. or higher and 2600 ° C. or lower.
- the silicidation can be performed at a lower temperature as the particle size of silicon used is smaller, silicidation takes longer when the temperature is lower than 1100 ° C. If it exceeds 2600 ° C., silicon will be easily vaporized, and maintenance of a reduced pressure high temperature furnace corresponding to that will be required.
- the time for leaving at high temperature is preferably 3 minutes or more and less than 2 hours. The optimum conditions of temperature and time according to the reduced-pressure high-temperature furnace to be used may be determined by analyzing the powder produced in the preliminary experiment.
- nitriding a part of the surface of the tungsten powder there is a method in which the tungsten powder is placed at 350 to 1500 ° C. for about 1 minute to 10 hours under reduced pressure in a nitrogen gas atmosphere (usually 10 ⁇ 3 Pa or less). Nitriding may be performed on the tungsten molded body or the tungsten sintered body under the same conditions as in the case of the tungsten powder. For example, when it is a primary powder, nitriding may be performed at any time after granulated powder preparation or after sintered body preparation. Thus, although there is no limitation on the timing of nitriding, it is preferable to perform nitriding at an early stage of the process. If it does in this way, when handling powder in the air, oxidation more than necessary can be prevented.
- the amount of nitriding is preferably such that 0.01 to 0.5 mass%, more preferably 0.05 to 0.3 mass% of nitrogen remains in the anode body. If the primary powder is to be nitrided, the amount of nitridation may be adjusted by using the same amount or twice the target content in the anode body. That is, a preliminary test is performed in the range of 0.01 to 1% by mass as the nitriding amount of the primary powder, and the above-mentioned preferable content as the anode body can be obtained.
- the nitrogen content includes nitrogen that is not chemically bonded to tungsten (for example, nitrogen in solid solution) in addition to nitrogen that is bonded to tungsten.
- the tungsten powder is subjected to reduced pressure (usually 10 ⁇ 3 Pa or less) at 300 to 1500 ° C. for 1 minute to 10 in a reduced pressure high temperature furnace using a carbon electrode.
- reduced pressure usually 10 ⁇ 3 Pa or less
- the carbon content can be adjusted.
- Carbonization is preferably performed so that the carbon content in the obtained anode body is preferably 0.001 to 0.1% by mass, more preferably 0.01 to 0.1% by mass.
- the carbonization time is the same as the nitriding time described above. However, since carbon remains in the anode body with a good yield, the carbon content can be adjusted to the above range regardless of the carbonization period.
- nitrogen gas is passed in a carbon electrode furnace under predetermined conditions, carbonization and nitridation occur simultaneously, and it is also possible to produce tungsten powder having a part of the surface nitrided and carbonized.
- a method for boring a part of the surface of tungsten powder there is a method of granulating by placing boron element or a compound containing boron element as a boron source when granulating tungsten powder. It is preferable to add the boron source so that the content in the obtained anode body is preferably 0.001 to 0.1% by mass, more preferably 0.01 to 0.1% by mass. Within this range, good LC characteristics can be obtained.
- nitrided or carbonized powder When silicified, nitrided or carbonized powder is put into a carbon electrode furnace and a boron source is placed and granulated, part of the surface is silicided and borated, nitrided and borated, or carbonized and borated tungsten powder. It is also possible to produce it. When a predetermined amount of boriding is performed, LC may be further improved. Thus, at any time during the manufacturing process of the anode body, a part of the surface of the anode body contains at least one compound selected from tungsten nitride, tungsten carbide, and tungsten boride. It is preferable to provide a process.
- a sintered body of this tungsten powder (primary powder or granulated powder) is used as a base material (anode body) of a capacitor, a dielectric layer is formed on the surface layer of the electrode, and a semiconductor serving as the other electrode thereon A layer is provided to form a tungsten capacitor element.
- a dielectric layer and a semiconductor layer are sequentially formed on the anode body by chemical conversion and electrolytic polymerization.
- a capacitor element formed by sequentially forming a dielectric layer and a semiconductor layer on the anode body may be used as it is as a capacitor element.
- a capacitor layer is provided by providing a conductor layer in which a carbon layer and a silver layer are sequentially laminated on the semiconductor layer.
- the present inventor found that the leakage current characteristic of the capacitor element produced by carrying out restoration conversion in an aqueous chemical solution before forming the carbon layer and forming the silver layer is I found it to be good.
- the carbon layer in this case is preferably a carbon layer made of carbon and a hydrophilic resin. If a carbon layer made of carbon and a water-repellent resin is used for the carbon layer, when restoration conversion is performed in the chemical conversion aqueous solution, the carbon layer repels the chemical conversion aqueous solution and appears to have been repaired. May not repair the dielectric layer in the vicinity of the center of the base material, and even if a surfactant is added to the chemical conversion aqueous solution, it is difficult to achieve complete repair.
- Such a carbon layer can be formed by laminating a carbon paste made of an aqueous resin solution containing carbon particles on a semiconductor layer, for example, by dipping in a carbon paste, applying a carbon paste, or the like, and then drying.
- a carbon paste made of an aqueous resin solution containing carbon particles on a semiconductor layer
- the carbon particles used in the present invention include a powder obtained by mixing graphite and carbon black.
- conventionally known carbon is used, but hydrophilic carbon is preferable.
- the content of carbon particles in the carbon paste is usually in the range of 10 to 50% by mass.
- the resin used for the carbon paste examples include vinyl alcohol resin, water-soluble acrylic resin, ethylene oxide resin, carboxyvinyl resin, hydroxycellulose resin, modified alkyd resin, water-soluble phenol resin, water-soluble amideimide resin, and these And hydrophilic resins such as derivatives thereof. Usually, after the resin is dissolved in water in the range of 1 to 20% by mass, a predetermined amount of carbon is added to prepare.
- the chemical conversion treatment conditions are determined so that the carbon layer is not detached and dropped in the chemical conversion liquid during the repair chemical conversion treatment.
- the chemical conversion treatment time is preferably 1 to 40 minutes, more preferably 4 to 30 minutes, still more preferably 4 to 25 minutes.
- the formation current density is preferably 0.05 mA / piece to 2.5 mA / piece, more preferably 0.1 to 2 mA / piece, and still more preferably 0.1 to 1 mA / piece.
- the chemical conversion treatment temperature is preferably 0 to 40 ° C, more preferably 1 to 30 ° C, still more preferably 3 to 30 ° C.
- the processing time, current density, and temperature are within the ranges specified above, the desorption and dropping of the carbon layer into the chemical conversion liquid can be reduced.
- the chemical conversion liquid for performing the repair chemical conversion treatment is an aqueous electrolyte solution.
- the electrolyte include mineral acids, organic acids, various alkalis, and salts thereof.
- sulfuric acid is used.
- Two or more electrolytes in the chemical conversion liquid may be used in combination.
- 10 mass% or less of water-soluble alcohols such as ethylene glycol may be added to the chemical conversion liquid.
- the chemical conversion treatment may be performed in a plurality of times. In that case, you may use multiple types of chemical conversion liquid.
- the electrolytic capacitor is obtained by electrically connecting one or a plurality of anodes of the capacitor element of the present invention subjected to the repair conversion treatment to the anode terminal and the conductor layer to the cathode terminal, and then covering the resin.
- Example 1 A tungsten powder having an average particle diameter of 1 ⁇ m obtained by hydrogen reduction of tungsten oxide was mixed well with 0.3% by mass of commercially available silicon powder (average particle diameter of 1 ⁇ m), and then allowed to stand at 1380 ° C. for 30 minutes under a reduced pressure of 10 ⁇ 3 Pa. Then, the temperature was returned to room temperature and air was gradually introduced to take out. Crushing with a hammer mill gave granulated powder having a particle size of 20 to 150 ⁇ m (volume average particle size of 105 ⁇ m). The granulated powder was molded using a molding machine. At the time of molding, a separately prepared 0.29 mm ⁇ tungsten wire was planted in the molded body.
- the obtained molded body was allowed to stand at 1520 ° C. for 20 minutes under a reduced pressure of 10 ⁇ 3 Pa, returned to room temperature, gradually introduced with air and taken out, with a size of 1.0 ⁇ 1.5 ⁇ 4.5 mm (lead A plurality of sintered bodies having a line of 1.0 ⁇ 1.5 mm and having a diameter of 3.5 mm inside and 8 mm outside are prepared. A tetrafluoroethylene washer was inserted into the lead wire.
- the sintered body was applied in a chemical conversion liquid (0.1% sulfuric acid aqueous solution), a lead wire of the sintered body was used as an anode, a separate electrode provided in the chemical conversion liquid was used as a cathode, and a voltage of 10 V was applied at room temperature (20 (C) for 10 hours.
- a dielectric layer was formed on a part of the lead wire and the sintered body.
- the sintered body was washed with water and dried. After immersing the sintered body in a 20% by mass ethylenedioxythiophene ethanol solution, a separately prepared polymerization solution (into a mixed solvent consisting of 30 parts by mass of water and 70 parts by mass of ethylene glycol, 0.4% by mass ethylenedioxythiophene and The solution was electropolymerized at 20 ° C. for 1 hour in a solution containing 0.6 mass% anthraquinonesulfonic acid. During the electropolymerization, the applied voltage value and current density are 10V and 44 ⁇ A / piece for the first 15 minutes (0 to 15 minutes), 10 V and 82 ⁇ A / piece for the next 15 minutes (15 to 30 minutes), and then 30 minutes.
- the LC value in the chemical conversion liquid per sintered body after 15 minutes was 1.5 ⁇ A. After the restoration conversion treatment, it was washed with water, washed with ethanol, and dried. Subsequently, a silver layer was laminated on the carbon layer in accordance with a conventional method to produce 320 solid electrolytic capacitor elements. The average capacity was 290 ⁇ F.
- Comparative Example 1 320 solid electrolytic capacitor elements were produced in the same manner as in Example 1 except that after the carbon layer was formed in Example 1, no restoration conversion was performed.
- Examples 2-11 320 solid electrolytic capacitor elements were produced in each example in the same manner as in Example 1 except that the current density value, temperature, and time for repair formation after forming the carbon layer were changed as shown in Table 1.
- Example 12 The carbon paste in Example 1 is 25 parts by mass of carbon obtained by mixing natural graphite having a volume average particle size of 2 ⁇ m and a particle size distribution of 0.2 to 150 ⁇ m, 5% by mass of carbon black, and 0.5% of nanotubes;
- a solid electrolytic capacitor element was produced in the same manner as in Example 1 except that a carbon paste composed of 75 parts by mass of an aqueous solution in which 2% by mass of hydroxycellulose resin SE550 was dissolved was used.
- Example 13 In Example 1, a powder having a volume average particle size of 0.7 ⁇ m was prepared using ammonium tungstate instead of tungsten oxide powder, and the lump obtained by leaving at 1450 ° C. for 30 minutes under reduced pressure was crushed with a hammer mill. A sintered body was obtained in the same manner as in Example 1 except that the granulated powder was a granulated powder having a particle size of 30 to 180 ⁇ m (volume average particle size 115 ⁇ m) and sintered at 1590 ° C. instead of 1520 ° C. A solid electrolytic capacitor element was produced. The average capacity was 380 ⁇ F.
- Comparative Example 2 A solid electrolytic capacitor element was produced in the same manner as in Example 13 except that Electrodag (registered trademark) PR406 (water repellent resin butyl carbinol solution) manufactured by Atchison Co. was used as the carbon paste in Example 13.
- Electrodag registered trademark
- PR406 water repellent resin butyl carbinol solution
- Table 1 shows the LC ( ⁇ A) and average capacity ( ⁇ F) of the solid electrolytic capacitor elements produced in Examples 1 to 13 and Comparative Examples 1 and 2, and the conditions for the repair conversion treatment process (current density, treatment time, treatment). Table 1 together with the temperature.
- the capacity was measured using an Agilent LCR meter at room temperature, 120 Hz, and a bias value of 2.5V.
- the LC value was measured 30 seconds after applying 2.5 V at room temperature.
- the leakage current is the average value after 30 seconds of application of room temperature 2.5 V, measured by lightly contacting the lead wire of the solid electrolytic capacitor element with the anode and the silver layer with the cathode lead wire from the external power source. It is.
- CV ⁇ A is indicated by the product of the capacitance of the capacitor element, the rated voltage of 2.5 V, and the LC current value.
- Examples 8 to 11 are examples where the processing temperature, the processing time, or the current density specified in the claims is a specified limit value. This is because part of the carbon is desorbed in the liquid during the subsequent chemical conversion treatment, and at that time, there are things that adversely affect the dielectric layer through the semiconductor layer, but there are also yield products that have no problem in performance (average capacity). Has been obtained.
- Example 13 The reason why the yield and leakage current of Comparative Example 2 were worse than Example 13 was that the carbon layer was formed using a carbon paste made of carbon and a water-repellent resin. This carbon layer may repel the aqueous chemical solution and may not repair the dielectric layer of the substrate.
- a carbon layer containing a hydrophilic insulating resin cannot be converted because the resin dissolves in water when left in water, but within the preferable predetermined conditions of the present invention (Examples 1 to 7, In Examples 12 to 13), the carbon layer does not desorb into the liquid, or even if a slight desorption occurs, the tungsten dielectric layer is not affected specifically. Defective products due to large leakage current including short circuits are not confirmed, and it can be seen that the yield is good.
- An electrolytic capacitor based on tungsten can be realized, raw material costs can be reduced, and high-capacity capacitors can be supplied.
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Abstract
Description
このようなコンデンサとしては、陽極酸化が可能なタンタルなどの弁作用金属粉末の焼結体からなる電極を陽極酸化して、この電極の表面にこれらの金属酸化物からなる誘電体層を形成した電解コンデンサが提案されている。
弁作用金属としてタングステンを用い、タングステン粉の焼結体を陽極体とする電解コンデンサは、同一粒径のタンタル粉を用いた同体積の陽極体、同化成電圧で得られる電解コンデンサに比較して、大きな容量を得ることができるが、漏れ電流(LC)が大きく電解コンデンサとして実用に供されなかった。このことを改良するために、タングステンと他の金属との合金を用いたコンデンサが検討されているが漏れ電流は幾分改良されるものの十分ではなかった(特開2004-349658号公報(米国特許第6876083号明細書);特許文献1)。
タンタルやアルミを基材とする固体電解コンデンサでは、一般に、半導体層を形成後に化成用水溶液中で修復化成を行うことにより、漏れ電流のない安定したコンデンサ素子となるためカーボン層を形成し銀層を形成する前には水を主成分とする化成液中で修復のための化成(修復化成)を行わないが、本発明者は、タングステンを基材とする固体電解コンデンサについて、カーボン層を形成し銀層を形成する前に化成用水溶液中で修復化成を行うと作製したコンデンサ素子の漏れ電流特性は良好になることを見出し本発明を完成した。
[1]タングステン基材上に、誘電体層、半導体層、カーボン層、及び銀層を順次形成する固体電解コンデンサ素子の製造方法において、カーボン層の形成がカーボンペーストを半導体層上に積層することにより行なわれ、前記カーボンペーストがカーボン粒子を含む樹脂水溶液であり、カーボン層形成後銀層形成前に修復化成処理を行うことを特徴とするコンデンサ素子の製造方法。
[2]修復化成処理の時間が1分以上40分以内である前項1に記載のコンデンサ素子の製造方法。
[3]修復化成処理の電流密度が0.05mA/個以上2.5mA/個以下である前項1または2に記載のコンデンサ素子の製造方法。
[4]修復化成処理の温度が0℃以上40℃以下である前項1または2に記載のコンデンサ素子の製造方法。
[5]修復化成処理の時間が1分以上40分以内であり、修復化成処理の電流密度が0.05mA/個以上2.5mA/個以下であり、かつ修復化成処理の温度が0℃以上40℃以下である前項1に記載のコンデンサ素子の製造方法。
[6]タングステン基材として、タングステン酸アンモニウムを還元して得たタングステン粉末の焼結体を用いる前項1に記載のコンデンサ素子の製造方法。
[7]樹脂が、ビニルアルコール樹脂、水溶性アクリル樹脂、エチレンオキシド樹脂、カルボキシビニル樹脂、ヒドロキシセルロース樹脂、変性アルキッド樹脂、水溶性フェノール樹脂、及び水溶性アミドイミド樹脂から選ばれる少なくとも1種である前項1~6のいずれかに記載のコンデンサ素子の製造方法。
これらの中でも、タングステン酸アンモニウムを原料とし、還元剤を使用して還元条件を適宜選択することによって調製したタングステン粉は、平均粒径が0.7μmとより小さい粉を、同原料から簡易に作製できる。加えて酸化タングステンを水素還元して得られる平均粒径1μmのタングステン粉よりも小さいので、より高容量のコンデンサを作製できることから好ましい。
このような造粒粉は、ふるいで分級して粒径を揃えることができる。体積平均粒径が好ましくは50~200μm、より好ましくは100~200μmの範囲であれば、成形機のホッパーから金型にスムーズに流れるために好都合である。
このような造粒粉を得る場合、例えば、前記一次粒子径を調整して、造粒粉の比表面積(BET法による)が、好ましくは0.2~20m2/g、より好ましくは1.5~20m2/gになるようにすると、電解コンデンサの容量をより大きくすることができ好ましい。
窒化は、タングステン粉の場合と同様の条件で、タングステン成形体またはタングステン焼結体に対して行ってもよい。例えば、一次粉のとき、造粒粉作製後、あるいは焼結体作製後のいずれかの時期に窒化を行ってもよい。このように、窒化の時期に限定は無いが、好ましくは、工程の早い段階で窒化しておくとよい。このようにすると、粉体を空気中で取り扱う際、必要以上の酸化を防ぐことができる。
なお、前記窒素含有量には、タングステンと結合している窒素以外に,タングステンと化学結合していない窒素(例えば、固溶している窒素)も含まれる。
このように、陽極体の製造工程中のいずれかの時期に、陽極体の表面の一部に、窒化タングステン、炭化タングステン、及びホウ化タングステンから選択される少なくとも1種の化合物を含有させるための工程を設けることが好ましい。
この場合のカーボン層は、カーボンと親水性の樹脂からなるカーボン層が好ましい。カーボン層に、カーボンと撥水性の樹脂からなるカーボン層を使用すると、化成用水溶液中で修復化成を行った場合、カーボン層が化成用水溶液をはじき、見かけ修復できたかのようになるが、実際には基材の中心近傍の誘電体層を修復していないことがあり、化成用水溶液に界面活性剤を加えて化成しても完全な修復には至ることが困難となる。
本発明では、修復化成処理の間に、カーボン層が化成液中に脱離落下しないように化成処理条件(化成時間、化成電流密度、化成温度)が決定される。
化成処理時間は、1~40分が好ましく、4~30分がより好ましく、4~25分が更に好ましい。化成電流密度は、0.05mA/個~2.5mA/個が好ましく、0.1~2mA/個がより好ましく、0.1~1mA/個が更に好ましい。化成処理温度は、0~40℃が好ましく、1~30℃がより好ましく、3~30℃が更に好ましい。上記に規定する範囲内の、処理時間、電流密度、及び温度であると、カーボン層の化成液中への脱離落下を少なく抑えられる。
酸化タングステンを水素還元して得た平均粒径1μmのタングステン粉に0.3質量%市販珪素粉(平均粒径1μm)をよく混合した後、10-3Paの減圧下1380℃で30分放置し、室温に戻して徐々に空気を投入して取り出した。ハンマーミルで解砕し、粒径20~150μm(体積平均粒径105μm)部分の造粒粉を得た。
造粒粉を成形器を用いて成形した。成形の際、別途用意した0.29mmφのタングステン線を成形体に植立した。
焼結体を、化成液(0.1%硫酸水溶液)中で、焼結体のリード線を陽極に、化成液中に別途設けた電極を陰極として、10Vの電圧を印加し、室温(20℃)で10時間化成処理した。これによりリード線の一部と焼結体に誘電体層を形成した。
実施例1でカーボン層形成後、修復化成を行わなかった以外は実施例1と同様にして固体電解コンデンサ素子を320個作製した。
カーボン層形成後の修復化成の電流密度値、温度、時間を表1のように変更した以外は実施例1と同様にして固体電解コンデンサ素子を各例320個作製した。
実施例1でカーボンペーストを、体積平均粒径2μmで粒度分布0.2~150μmの天然黒鉛と5質量%のカーボンブラックと0.5%のナノチューブを混合したカーボン25質量部と、ダイセル社製ヒドロキシセルロース樹脂SE550を2質量%を溶解した水溶液75質量部からなるカーボンペーストを使用した以外は実施例1と同様にして固体電解コンデンサ素子を作製した。
実施例1で酸化タングステン粉の代わりにタングステン酸アンモニウムを使用して体積平均粒径0.7μmの粉を作製し、減圧下1450℃で30分放置して得た塊状物をハンマーミルで解砕し粒径30~180μm(体積平均粒径115μm)部分の造粒粉とし、1520℃の代わりに1590℃で焼結した以外は実施例1と同様にして焼結体を得、さらに同様にして固体電解コンデンサ素子を作製した。平均容量は、380μFであった。
実施例13でカーボンペーストとして、アチソン社製エレクトロダッグ(登録商標)PR406(撥水性樹脂のブチルカルビノール溶液)を使用した以外は実施例13と同様にして固体電解コンデンサ素子を作製した。
実施例8~11で歩留まりが悪くなっているのは、これらの実施例が請求項で規定する処理温度、処理時間、電流密度のいずれかが規定の限界値の例であって、カーボン層形成後の化成処理の際に一部カーボンが液中に脱離し、そのときに半導体層を通して誘電体層に悪影響を及ぼすものがあるためであるが、性能(平均容量)に問題のない歩留り品も得られている。
Claims (7)
- タングステン基材上に、誘電体層、半導体層、カーボン層、及び銀層を順次形成する固体電解コンデンサ素子の製造方法において、カーボン層の形成がカーボンペーストを半導体層上に積層することにより行なわれ、前記カーボンペーストがカーボン粒子を含む樹脂水溶液であり、カーボン層形成後銀層形成前に修復化成処理を行うことを特徴とするコンデンサ素子の製造方法。
- 修復化成処理の時間が1分以上40分以内である請求項1に記載のコンデンサ素子の製造方法。
- 修復化成処理の電流密度が0.05mA/個以上2.5mA/個以下である請求項1または2に記載のコンデンサ素子の製造方法。
- 修復化成処理の温度が0℃以上40℃以下である請求項1または2に記載のコンデンサ素子の製造方法。
- 修復化成処理の時間が1分以上40分以内であり、修復化成処理の電流密度が0.05mA/個以上2.5mA/個以下であり、かつ修復化成処理の温度が0℃以上40℃以下である請求項1に記載のコンデンサ素子の製造方法。
- タングステン基材として、タングステン酸アンモニウムを還元して得たタングステン粉末の焼結体を用いる請求項1に記載のコンデンサ素子の製造方法。
- 樹脂が、ビニルアルコール樹脂、水溶性アクリル樹脂、エチレンオキシド樹脂、カルボキシビニル樹脂、ヒドロキシセルロース樹脂、変性アルキッド樹脂、水溶性フェノール樹脂、及び水溶性アミドイミド樹脂から選ばれる少なくとも1種である請求項1~6のいずれかに記載のコンデンサ素子の製造方法。
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JPS57154826A (en) * | 1981-03-19 | 1982-09-24 | Matsushita Electric Ind Co Ltd | Solid electrolytic condenser |
JPH05101988A (ja) * | 1991-10-08 | 1993-04-23 | Elna Co Ltd | 固体電解コンデンサの製造方法 |
JP2001237146A (ja) * | 2000-02-23 | 2001-08-31 | Matsushita Electric Ind Co Ltd | 固体電解コンデンサおよびその製造方法 |
JP2005325448A (ja) * | 2004-04-15 | 2005-11-24 | Jfe Mineral Co Ltd | タンタル粉末およびこれを用いた固体電解コンデンサ |
JP2008150251A (ja) * | 2006-12-19 | 2008-07-03 | Nippon Rensui Co Ltd | タングステン酸アンモニウム水溶液の製造方法 |
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US9530569B2 (en) | 2016-12-27 |
JPWO2013179996A1 (ja) | 2016-01-21 |
JP6012115B2 (ja) | 2016-10-25 |
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