WO2022114047A1 - 固体電解コンデンサ - Google Patents
固体電解コンデンサ Download PDFInfo
- Publication number
- WO2022114047A1 WO2022114047A1 PCT/JP2021/043139 JP2021043139W WO2022114047A1 WO 2022114047 A1 WO2022114047 A1 WO 2022114047A1 JP 2021043139 W JP2021043139 W JP 2021043139W WO 2022114047 A1 WO2022114047 A1 WO 2022114047A1
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- WO
- WIPO (PCT)
- Prior art keywords
- lead terminal
- solid electrolytic
- electrolytic capacitor
- layer
- copper
- Prior art date
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Images
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
- H01G9/004—Details
- H01G9/008—Terminals
- H01G9/012—Terminals specially adapted for solid capacitors
-
- 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
- H01G9/08—Housing; Encapsulation
- H01G9/10—Sealing, e.g. of lead-in wires
-
- 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
- This disclosure relates to solid electrolytic capacitors.
- the solid electrolytic capacitor includes a capacitor element provided with a solid electrolyte layer, a lead terminal electrically connected to the capacitor element, and an exterior body for sealing the capacitor element.
- the exterior body suppresses the deterioration of the condenser element by the oxygen and moisture in the atmosphere reaching the condenser element.
- the adhesion between the lead terminal and the exterior body is low, oxygen and moisture easily enter from the interface, and the solid electrolytic capacitor deteriorates.
- Patent Document 1 Japanese Unexamined Patent Publication No. 4-253314 states that "an oxide film, a conductive material layer, a conductive polymer film, and a conductor layer are sequentially formed on the surface of a valve metal to form a capacitor element, and this capacitor element is formed.
- the lead frame In a solid electrolytic capacitor in which a lead frame serving as a lead-out terminal is connected to the valve metal portion and the conductor layer portion of the above, and the capacitor element and a part of the lead frame are covered with a mold resin, the lead frame has a copper metal layer on the surface.
- the solid electrolytic capacitor according to one aspect of the present disclosure is electrically connected to at least one capacitor element including an anode portion and a cathode portion, an anode lead terminal electrically connected to the anode portion, and the cathode portion.
- a lead terminal including a cathode lead terminal and an exterior body covering the condenser element are included, and the anode lead terminal and the cathode lead terminal are connected to an embedded portion embedded in the exterior body and the embedded portion, respectively.
- the embedded portion of the anode lead terminal has a contact surface p that comes into contact with the exterior body, and the embedded portion of the cathode lead terminal includes an exposed portion that is exposed from the exterior body.
- the contact surface n that comes into contact with the exterior body is provided, and at least one contact surface selected from the contact surface p and the contact surface n has a rough surface having a developed area ratio of the interface of 0.4 or more.
- a solid electrolytic capacitor capable of particularly suppressing deterioration due to intrusion of oxygen or the like can be obtained.
- FIG. 1 is a cross-sectional view schematically showing an example solid electrolytic capacitor according to the embodiment of the present disclosure.
- FIG. 2 is an image of an example showing the state of the rough surface of the capacitor C2.
- FIG. 3 is an image of an example showing the state of the rough surface of the capacitor A2.
- one of the objects of the present disclosure is to provide a novel solid electrolytic capacitor capable of particularly suppressing deterioration due to intrusion of oxygen or the like.
- the present disclosure provides an electrolytic capacitor and a paste for forming a conductive layer of the electrolytic capacitor in order to provide a solid electrolytic capacitor capable of particularly suppressing deterioration due to intrusion of oxygen or the like.
- the solid electrolytic capacitor according to the present embodiment includes at least one capacitor element including an anode portion and a cathode portion, an anode lead terminal electrically connected to the anode portion, and a cathode electrically connected to the cathode portion.
- a lead terminal including a lead terminal and an exterior body covering the capacitor element are included.
- the anode lead terminal and the cathode lead terminal each include an embedded portion embedded in the exterior body and an exposed portion connected to the embedded portion and exposed from the exterior body.
- the embedded portion of the anode lead terminal has a contact surface p that comes into contact with the exterior body.
- the embedded portion of the cathode lead terminal has a contact surface n that comes into contact with the exterior body.
- At least one contact surface selected from the contact surface p and the contact surface n has a rough surface having an interface development area ratio of 0.4 or more.
- a rough surface having an interface development area ratio of 0.4 or more may be referred to as a "rough surface (R)" below.
- the developed area ratio of the interface can be measured by the method described later.
- the rough surface (R) is formed from the boundary between the embedded portion and the exposed portion to the inside of the exterior body.
- the rough surface (R) may be formed from the embedded portion to the exposed portion so as to be formed on at least a part of the exposed portion.
- the position of the outer surface of the exterior body may shift.
- the length L of the rough surface (R) from the boundary between the embedded portion and the exposed portion is preferably 0.3 mm or more, even if it is 0.5 mm or more. good.
- the length L is a length along the surface of the exposed portion, and is an apparent length when the surface of the exposed portion is assumed to be smooth.
- the upper limit of the length L is not particularly limited, and the entire surface of the exposed portion may be a rough surface (R).
- At least one selected from the contact surface p and the contact surface n has a rough surface (R).
- each of the contact surface p and the contact surface n has a rough surface (R).
- the effect of the present disclosure can be enhanced by increasing the ratio of the rough surface (R) to the contact surface.
- the ratio of the area of the rough surface (R) to the area of the contact surface p is preferably 50% or more, more preferably 80% or more (for example, 90% or more).
- the ratio of the area of the rough surface (R) to the area of the contact surface n is preferably 50% or more, more preferably 80% or more (for example, 90% or more). All of the contact surface p and the contact surface n may be rough surfaces (R).
- the area here is an apparent area, which is an area assuming that the surface is smooth.
- the surface of the lead terminal may have a rough surface (R) on a surface other than the contact surface in contact with the exterior body.
- the surface electrically connected to the cathode portion may be a rough surface (R) having a developed area ratio of the interface of 0.4 or more.
- the ratio of the area of the rough surface (R) to the area of the surface of the embedded portion may be 50% or more, 80% or more, or 90% or more.
- the entire surface of the embedded portion may be a rough surface (R).
- the developed area ratio of the interface of the rough surface (R) is 0.4 or more.
- the lead terminal can be easily manufactured by setting the developed area ratio to a certain value or less.
- the developed area ratio of the interface of the rough surface (R) may be 10.0 or less, 6.0 or less, 4.0 or less, 2.0 or less, 1.0 or less, or 0.6 or less.
- the developed area ratio of the interface may be in the range specified by any of the upper limit described here and the lower limit (0.4 or more).
- the developed area ratio of the interface of the rough surface (R) is in the range of 0.4 to 10.0, the range of 0.4 to 6.0, the range of 0.4 to 4.0, and 0.4 to 4.0. It may be in the range of 2.0, 0.4 to 1.0, or 0.4 to 0.6.
- a preferable example of the solid electrolytic capacitor according to the present disclosure may satisfy the following conditions (1) and (2), and further satisfy the condition (3).
- the ratio of the area of the rough surface (R) to the area of the contact surface p and the ratio of the area of the rough surface (R) to the area of the contact surface n are 50% or more and 80% or more (for example). 90% or more). All of the contact surface p and the contact surface n may be rough surfaces (R). In this condition (1), the area of the contact surface p and the area of the contact surface n may be read as the area of the embedded portion of the anode lead terminal and the area of the embedded portion of the cathode lead terminal, respectively.
- the developed area ratio of the interface of the rough surface (R) is 0.4 or more.
- the developed area ratio of the interface may be 10.0 or less, and may be within the above-exemplified range.
- the rough surface (R) is formed from the boundary between the embedded portion and the exposed portion to the inside of the exterior body.
- the rough surface (R) may be formed from the embedded portion to the exposed portion so as to be formed on at least a part of the exposed portion.
- At least one base material selected from the base material of the anode lead terminal and the base material of the cathode lead terminal may be a copper base material. In that case, at least a part of the copper base material in the exposed portion may be covered with the copper plating layer.
- both the base material of the anode lead terminal and the base material of the cathode lead terminal are copper base materials. In that case, at least a part of both copper substrates may be coated with a copper plating layer. The entire surface of the exposed portion may be covered with a copper plating layer.
- a rolled copper plate can be used as the copper base material (lead frame).
- the rolled copper plate has a structure extending along the rolling direction.
- the direction of the ridge line at the bending position of the lead terminal and the direction in which the structure extends may be substantially parallel depending on the direction in which the rolled copper plate is punched.
- the space between the tissues is widened by bending, and cracks may occur.
- the plating layer (for example, the tin plating layer) formed on the copper base material receives tensile stress and cracks are generated in the plating layer, which may reduce the wettability of the solder.
- an alloy layer of copper and tin is formed between the copper base material and the tin-plated layer due to the heat at the time of mounting. Since the alloy layer of copper and tin is harder and harder to extend than copper and tin, the stress generated by the cracks in the copper substrate cannot be relaxed, and the alloy layer is liable to crack. As a result, the tin-plated layer may also be cracked, and the wettability of the solder may be reduced. By forming the copper plating layer on the copper base material, the stress due to cracks in the copper base material can be relieved by the copper plating layer having excellent ductility.
- the copper plating layer has a good affinity with a copper base material containing copper as a main component, and easily fills irregularities caused by cracks in the copper base material. As a result, the generation of cracks in the copper plating layer and the plating layer covering the copper plating layer is suppressed, and the deterioration of the wettability of the solder is suppressed. Therefore, the reliability of the electrical connection between the solid electrolytic capacitor and the external substrate can be improved. Since the copper plating layer has a structure perpendicular to the spreading direction of the copper base material, for example, the copper base material and the copper plating layer covering the copper base material can be distinguished by microscopic observation, and the copper base material and the copper plating layer can be distinguished. The boundary with and can be identified.
- the thickness of the copper plating layer is preferably 2 ⁇ m or more.
- the thickness of the copper plating layer may be, for example, 10 ⁇ m or less or 15 ⁇ m or less.
- the copper base material may have a bent portion that is bent along the outer surface of the exterior body in the exposed portion.
- the outer surface of the bent portion may be covered with a copper plating layer. Since high stress is applied to the bent portion, it is preferable to cover the bent portion with a copper plating layer.
- the solid electrolytic capacitor (more specifically, the lead terminal) may further include a tin-plated layer covering the copper-plated layer.
- the solid electrolytic capacitor (more specifically, the lead terminal) may further include another layer arranged between the copper-plated layer and the tin-plated layer.
- the other layer may be an alloy layer of copper and tin or a nickel-plated layer.
- the tin-plated layer can enhance the wettability of the solder and enhance the reliability of the electrical connection between the solid electrolytic capacitor and the external substrate.
- tin (Sn) in the tin-plated layer diffuses into the copper-plated layer due to the heat at the time of mounting, and copper and copper are formed between the copper-plated layer and the tin-plated layer.
- An alloy layer with tin may be formed.
- a nickel plating layer may be formed between the copper plating layer and the tin plating layer.
- the solid electrolytic capacitor (more specifically, the lead terminal) according to the present embodiment may further include a noble metal plating layer covering the copper plating layer.
- the noble metal plating layer may contain at least one selected from the group consisting of gold, platinum, and palladium.
- the solid electrolytic capacitor (more specifically, the lead terminal) according to the present embodiment may further include a nickel plating layer arranged between the copper plating layer and the noble metal plating layer.
- the layer formed on the base material of the lead terminal (such as the plating layer described above) may be referred to as a “coating layer”.
- Examples of components of capacitor elements An example of a component of a capacitor element (solid electrolytic capacitor element) will be described below.
- Known constituent members may be applied to the constituent members other than the portions characteristic of the present disclosure.
- the capacitor element is not particularly limited as long as the effect of the present disclosure can be obtained, and a capacitor element other than the capacitor element described below (for example, a known capacitor element) may be used.
- the anode portion includes an anode body.
- the anode body can include a valve acting metal, an alloy containing a valve acting metal, a compound containing a valve acting metal, and the like. These materials may be used alone or in combination of two or more.
- As the valve acting metal for example, aluminum, tantalum, niobium, and titanium are preferably used.
- the anode body having a porous portion on the surface is obtained, for example, by roughening the surface of a metal foil containing a valve acting metal. The roughening may be performed by electrolytic etching or the like. The entire anode may be porous.
- the anode includes a porous portion arranged on both main surfaces and a core portion arranged between the porous portions.
- the porosity of the core portion is lower than the porosity of the porous portion.
- the porous portion is a region having a large number of fine pores.
- the core portion is, for example, a region that has not been electrolytically etched.
- the capacitor element includes a dielectric layer disposed between the anode portion and the cathode portion.
- the dielectric layer is an insulating layer that functions as a dielectric.
- the dielectric layer may be formed by anodizing the valvening metal on the surface of the anode (eg, metal leaf).
- the dielectric layer may be formed so as to cover at least a part of the anode body (anode portion).
- the dielectric layer is usually formed on the surface of the anode. Since the dielectric layer is formed on the surface of the porous portion of the anode body, it is formed along the inner wall surface of holes and depressions (also referred to as pits) on the surface of the anode body.
- a typical dielectric layer contains an oxide of a valvening metal.
- a typical dielectric layer when tantalum is used as the valve acting metal contains Ta 2 O 5
- a typical dielectric layer when aluminum is used as the valve acting metal contains Al 2 O 3 .
- the dielectric layer is not limited to this, and may be any one that functions as a dielectric.
- the cathode portion includes a solid electrolyte layer that covers at least a part of the dielectric layer, and may further include a cathode extraction layer that covers at least a part of the solid electrolyte layer.
- a cathode extraction layer that covers at least a part of the solid electrolyte layer.
- Solid electrolyte layer As the solid electrolyte layer, for example, a layer containing a conductive polymer can be used.
- the solid electrolyte layer may optionally contain at least one selected from the group consisting of dopants and other additives, in addition to the conductive polymer.
- dopant include, but are not limited to, paratoluenesulfonic acid, naphthalenesulfonic acid, and polystyrene sulfonic acid (PSS).
- the conductive polymer for example, a ⁇ -conjugated polymer can be used.
- the conductive polymer include polymers having polypyrrole, polythiophene, polyaniline, polyfuran, polyacetylene, polyphenylene, polyphenylene vinylene, polyacene, and polythiophene vinylene as basic skeletons.
- the above polymers also include homopolymers, copolymers of two or more monomers, and derivatives thereof (such as substituents having substituents).
- polythiophene includes poly (3,4-ethylenedioxythiophene) and the like. However, these are just examples, and conductive polymers are not limited to these examples.
- a conductive layer can be used as the cathode extraction layer.
- a layer containing conductive particles, a metal foil, or the like may be used as the cathode extraction layer.
- conductive particles include conductive carbon and metal particles.
- the cathode extraction layer may include a first layer and a second layer laminated in order from the side of the solid electrolyte layer.
- a layer containing conductive carbon may be used as the first layer, and a layer containing metal particles or a metal foil may be used as the second layer.
- Examples of conductive carbon include graphite (artificial graphite, natural graphite, etc.).
- metal particles include silver particles and the like.
- the layer containing the conductive particles may be formed by using a composition containing the conductive particles and a resin (binder resin), or may be formed by using a metal paste (for example, silver paste).
- the solid electrolytic capacitor according to this embodiment includes at least one capacitor element.
- the number of capacitor elements included in the solid electrolytic capacitor may be in the range of 1 to 20 (for example, the range of 2 to 10).
- the capacitor elements may be laminated.
- the ends of the anodes of the laminated capacitor elements are electrically connected to each other.
- the ends of those anodes may be joined by welding.
- Anode lead terminals may be connected to the ends of those anodes.
- a cathode lead terminal may be bonded to the cathode lead-out layer of at least one capacitor element.
- the cathode lead terminal may be bonded to the cathode lead-out layer via a conductive adhesive or solder.
- the cathode lead terminal may be joined to the cathode lead-out layer by welding (resistance welding, laser welding, etc.).
- the conductive adhesive is, for example, a mixture of a curable resin and carbon particles or metal particles.
- the solid electrolytic capacitor includes an exterior body that covers the capacitor element.
- the exterior body also covers a part of the anode lead terminal (embedded part) and a part of the cathode lead terminal (embedded part).
- the exterior body preferably contains a cured product of a curable resin composition, and may contain a thermoplastic resin or a composition containing the same.
- the curable resin composition may contain a curable resin and a filler.
- a thermosetting resin is preferable.
- the curable resin composition may contain a filler, a curing agent, a polymerization initiator, a catalyst and the like in addition to the curable resin.
- curable resins include epoxy resins, phenolic resins, urea resins, polyimides, polyamideimides, polyurethanes, diallyl phthalates, unsaturated polyesters and the like.
- the curable resin composition may contain a plurality of curable resins.
- fillers include insulating particles (inorganic particles, organic particles), insulating fibers, and the like.
- insulating materials constituting the filler include, for example, insulating compounds such as silica and alumina (oxides and the like), glass, mineral materials (talc, mica, clay and the like) and the like.
- the type of the filler contained in the exterior body may be only one type, or may be two or more types.
- the content of the filler in the exterior body may be in the range of 10 to 90% by mass.
- thermoplastic resin for example, polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), or the like can be used.
- the composition containing the thermoplastic resin may contain the above-mentioned filler and the like in addition to the thermoplastic resin.
- the solid electrolytic capacitor according to the present embodiment may further include a case arranged outside the exterior body (resin composition).
- resin composition a case arranged outside the exterior body
- the resin material constituting the case include a thermoplastic resin or a composition containing the same.
- the metal material constituting the case include metals such as aluminum, copper, and iron, or alloys thereof (including stainless steel and brass).
- the anode lead terminal and the cathode lead terminal include an embedded portion and an exposed portion, respectively.
- the anode lead terminal and the cathode lead terminal can be formed by a known material and a known method except for the rough surface (R) portion.
- the anode lead terminal and the cathode lead terminal may be formed by processing a metal sheet (including a metal plate and a metal foil) made of a metal (copper, copper alloy, etc.), respectively. That is, examples of the material of the base material of the anode lead terminal and the cathode lead terminal include copper, copper alloy, and the like.
- One end of the anode lead terminal (the end of the embedded part) is connected to the anode part.
- One end of the cathode lead terminal (the end of the embedded portion) is connected to the cathode portion (for example, the cathode extraction layer).
- the exposed portion of the anode lead terminal and the exposed portion of the cathode lead terminal can each function as terminal portions to be soldered or the like when a solid electrolytic capacitor is mounted.
- the method for manufacturing the solid electrolytic capacitor according to the present embodiment is not particularly limited.
- a known production method may be applied to these production methods, except for the method of forming the rough surface (R), or a part of the known production method may be modified and applied.
- the solid electrolytic capacitor according to this embodiment may be manufactured by a method other than the method described below. Since the matters described about the solid electrolytic capacitor can be applied to the following manufacturing methods, duplicate description may be omitted. Further, the matters described about the following manufacturing method can be applied to the solid electrolytic capacitor according to the present embodiment.
- a capacitor element, an anode lead terminal, and a cathode lead terminal are manufactured (step (i)).
- the method for manufacturing the capacitor element is not particularly limited, and the capacitor element can be formed by a known method.
- a solid electrolytic capacitor including a plurality of laminated capacitor elements a plurality of capacitor elements are laminated. In that case, if necessary, the anode portions of the plurality of capacitor elements are connected to each other by welding or the like. Further, if necessary, the cathode portions of the plurality of capacitor elements are connected to each other by a conductive paste or the like.
- the anode lead terminal is electrically connected to the anode portion of the capacitor element, and the cathode lead terminal is electrically connected to the cathode portion of the capacitor element (step (ii)).
- connection methods are not particularly limited, and known connection methods may be applied.
- the anode portion and the anode lead terminal may be connected by welding or the like.
- the cathode portion and the cathode lead terminal may be connected by a conductive paste or the like.
- the exterior body can be formed by using molding techniques such as injection molding, insert molding, and compression molding.
- This manufacturing method includes a step (I) of manufacturing a lead terminal (anode lead terminal and / or cathode lead terminal) having a rough surface (R).
- the step (I) includes a step (a) of processing the metal sheet (base material) into a predetermined shape by press working or the like, and a step (b) of forming a rough surface (R).
- the step (I) may further include a step (c) of forming a coating layer (plating layer or the like) on the substrate. Either step (a) or step (b) may come first.
- the steps (a), the step (b), and the step (c) are particularly in this order.
- the steps (a), the step (b), and the step (c) are particularly in this order.
- the coating layer is formed on the surface having the rough surface (R) after the rough surface (R) is formed, the developed area ratio of the interface of the rough surface (R) may decrease.
- the step (b) may be performed after the step (c) is performed.
- the step (c) may be performed in which the coating layer is formed only in the region that does not have to be the rough surface (R).
- step (c) may be performed before the step (iii) of covering the embedded portion of the capacitor element and the lead terminal with the exterior body. Alternatively, step (c) may be performed after step (iii) to form a coating layer only on the exposed portion of the lead terminal.
- the step (a) of processing a metal sheet (base material) into a predetermined shape by press working or the like can be performed by a known method.
- the step (b) for forming the rough surface (R) may be performed by, for example, a sandblasting method, a roughened plating method, a roughened etching method, or the like.
- the sandblasting method is preferable because it enables quick processing and is excellent in cost performance.
- the rough plating method is preferable in that the cost is low.
- the rough etching method is preferable in that it has less unevenness and can form fine roughness. Further, the rough plating method and the rough etching method have an advantage that beads (projection material) do not remain, unlike the sandblast method.
- the method of roughening the surface of the lead terminal by the sandblast method or the like has been conventionally performed. However, under the conventional conditions, the adhesion between the exterior body and the lead terminal is not sufficient. In the method of the present disclosure, roughening is performed under the condition that the developed area ratio of the interface of the rough surface is 0.4 or more.
- the particle size of the particles (projecting material) By reducing the particle size of the particles (projecting material) (for example, increasing the count), it is possible to increase the developed area ratio of the interface of the sandblasted surface. Therefore, in this method, sandblasting is usually performed using particles smaller than the particles conventionally used for roughening the lead terminal. Further, by increasing the number of shots of sandblasting, the ratio of the developed area of the interface of the sandblasted surface can be increased to some extent. If the particle size of the particles (projecting material) is made too small, the developed area ratio of the interface may become small, but the condition that the developed area ratio of the interface on the rough surface is 0.4 or more can be easily determined by experiment.
- the particles (projection material) used for sandblasting are not particularly limited, and alumina particles or garnet particles may be used.
- the Sdr can be set to 0.4 or more by, for example, forming needle-shaped or particle-shaped plating to increase the surface area.
- the proportion of needle-like or particle-like plating may be increased.
- the difference between the etching rate of the crystal grain boundaries and the etching rate of the crystal grains (the crystal grain boundaries have a high etching rate) is used for roughening.
- the surface area can be increased by forming the shape, and as a result, the Sdr can be 0.4 or more.
- the ratio of the crystal grain boundaries to the crystal grains in the metal may be changed by selecting the metal as the material of the lead terminal, or the difference in the etching rate may be changed by changing the etching conditions.
- a rough surface (R) having an interface development area ratio of 0.4 or more is formed on the lead terminal.
- the coating layer (layer on the substrate) formed in the step (c) may be formed by a known method (for example, a known plating method). In this way, a solid electrolytic capacitor can be manufactured.
- FIG. 1 is a cross-sectional view schematically showing a solid electrolytic capacitor according to the first embodiment.
- the solid electrolytic capacitor 10 shown in FIG. 1 includes a capacitor element 100, a lead terminal 20, and an exterior body 30.
- the lead terminal 20 includes an anode lead terminal 21 electrically connected to the anode portion (anode body) 111 of the capacitor element 100 and a cathode lead terminal 22 electrically connected to the cathode portion 113 of the capacitor element 100. ..
- the capacitor element 100 includes an anode portion (anode body) 111, a dielectric layer 112 that covers at least a part of the anode portion 111, and a cathode portion 113 that covers at least a part of the dielectric layer 112.
- the cathode portion 113 includes a solid electrolyte layer 113a that covers at least a part of the dielectric layer 112, and a cathode extraction layer 113b that covers at least a part of the solid electrolyte layer 113a.
- the anode lead terminal 21 includes an embedded portion 21a embedded in the exterior body 30 and an exposed portion 21b exposed from the exterior body 30.
- the cathode lead terminal 22 includes an embedded portion 22a embedded in the exterior body 30 and an exposed portion 22b exposed from the exterior body 30.
- FIG. 1 shows a boundary 21x between the embedded portion 21a and the exposed portion 21b, and a boundary 22x between the embedded portion 22a and the exposed portion 22b.
- the cathode portion 113 (specifically, the cathode extraction layer 113b) of the capacitor element 100 is electrically connected to the embedded portion 22a of the cathode lead terminal 22 by the conductive paste 23.
- the embedded portion 21a has a contact surface p that comes into contact with the exterior body 30.
- the embedded portion 22a has a contact surface n that comes into contact with the exterior body 30.
- the contact surface p and / or the contact surface n has the above-mentioned rough surface (R).
- R rough surface
- the adhesion between the exterior body 30 and the lead terminal 20 is enhanced. Therefore, it is possible to suppress the intrusion of oxygen or the like from the interface between the exterior body 30 and the lead terminal 20. As a result, deterioration of the capacitor element 100 can be suppressed, and long-term reliability of the solid electrolytic capacitor 10 can be enhanced.
- the anode lead terminal 21 and / or the cathode lead terminal 22 may include the coating layer described above.
- the covering layer is preferably formed so as to cover the bent portions 21d and 22d that are bent along the outer surface of the exterior body 30 in the exposed portions 21b and 22b.
- An example electrolytic capacitor according to this embodiment may include a plurality of stacked capacitor elements 100.
- one end of the anode portion 111 of the plurality of capacitor elements 100 is joined by welding or the like, and at least one anode portion 111 is connected to the anode lead terminal 21.
- the cathode portion 113 of the plurality of capacitor elements 100 is connected by a conductive paste or the like, and at least one cathode portion 113 is connected to the cathode lead terminal 22 by a conductive paste or the like. That is, the plurality of capacitor elements 100 are connected in parallel.
- the contact surface p and / or the contact surface n has a rough surface (R).
- Each solid electrolytic capacitor contains one capacitor element.
- the solid electrolytic capacitor and the capacitor element have a structure similar to that of the solid electrolytic capacitor 10 and the capacitor element 100 shown in FIG. 1, respectively.
- an anode body (anode portion) was produced by roughening both surfaces of an aluminum foil (thickness: 100 ⁇ m) by etching.
- a dielectric layer (aluminum oxide layer) was formed on the anode body by anodizing a part of the anode body in a state of being immersed in the chemical conversion solution.
- a solid electrolyte layer was formed on the dielectric layer by the following method.
- an aqueous solution containing a pyrrole monomer and p-toluenesulfonic acid was prepared.
- the anode body on which the dielectric layer was formed and the counter electrode were immersed in the obtained aqueous solution, and electrolytic polymerization was performed. By this electrolytic polymerization, a solid electrolyte layer was formed.
- the graphite particles and the dispersant were wet-ground together with water using a bead mill to obtain a dispersion liquid.
- This dispersion was applied to the surface of the solid electrolyte layer, and then dried. In this way, a carbon layer was formed on the surface of the solid electrolyte layer.
- a silver paste containing silver particles and a binder resin epoxy resin
- a cathode extraction layer including a carbon layer and a metal paste layer was formed. In this way, the capacitor element was manufactured.
- a copper sheet (thickness: 100 ⁇ m) for forming the anode lead terminal and the cathode lead terminal was prepared.
- a rough surface was formed by roughening the portion to be the embedded portion of the anode lead terminal and the portion to be the embedded portion of the cathode lead terminal.
- the metal sheet was processed to form the shape of the anode lead terminal and the shape of the cathode lead terminal.
- Roughening was performed by the sandblasting method, the roughened plating method, and the roughened etching method.
- Sdr was changed by changing the average particle size of the blast beads (projecting materials such as alumina particles and garnet particles).
- Sdr was increased by the above-mentioned method.
- the arithmetic mean height Sa and the developed area ratio Sdr of the interface were measured for the formed rough surface.
- the capacitor C1 which was not roughened the arithmetic average height Sa and the developed area ratio Sdr of the interface were measured for the surface roughness of the surface of the lead terminal.
- the developed area ratio Sdr of the interface was measured according to ISO25178.
- the arithmetic mean height Sa was measured according to ISO 25178.
- anode part of the capacitor element was connected to the anode lead terminal. Further, the cathode portion of the capacitor element was connected to the cathode lead terminal with a conductive paste. Next, the capacitor element, a part of the anode lead terminal (embedded part), and a part of the cathode lead terminal (embedded part) were covered by molding. In this way, an electrolytic capacitor having a structure similar to that of the electrolytic capacitor shown in FIG. 1 was manufactured.
- capacitors C1, C2, A1 to A5 seven types of solid electrolytic capacitors (capacitors C1, C2, A1 to A5) were manufactured 100 by 100 by changing the rough surface forming method (roughening method).
- Table 1 shows the roughening method used.
- the average particle size of the blast beads (projecting material) used was changed as shown in Table 1 below to change the developed area ratio of the interface.
- the average particle size of the blast beads used in the sandblasting of the capacitor C2 was used as a reference, and the ratio of the average particle size to the average particle size was changed as shown in Table 1.
- the average particle size of the blast beads used in the sand blasting of the capacitor A1 is half the average particle size of the blast beads used in the sand blasting of the capacitor C2.
- the condition for sandblasting the capacitor C2 is the condition for sandblasting that has been conventionally used.
- the produced capacitor was heat-treated under the same conditions as the solder reflow process (peak temperature was 260 ° C. for 10 seconds). Then, the airtightness defect rate was evaluated for the capacitor after the heat treatment.
- the airtightness defect rate was evaluated by the gross leak test. Specifically, a capacitor was placed inside the small capsule, and a minute pressure drop generated by the internal pressure inside the small capsule leaking into the outer body of the capacitor was measured. Then, the capacitor having a large pressure change was determined to have poor airtightness. Table 1 shows some of the capacitor manufacturing conditions and the evaluation results.
- the airtightness defect rate after the heat treatment could be significantly reduced. It can be seen that the arithmetic average height Sa of the surface of the capacitor C2 subjected to the sandblasting treatment is significantly increased as compared with the capacitor C1 and the surface is roughened by the sandblasting treatment. However, the airtightness defect rate of the capacitor C2 after the heat treatment was still high. Although the arithmetic mean height Sa of the rough surface of the capacitors A1 to A5 was lower than that of the capacitor C2, the airtightness failure rate of the capacitors A1 to A5 was significantly lower than that of the capacitor C2. .. This indicates that the evaluation method conventionally used has not been able to perform an appropriate evaluation.
- FIG. 2 An image of an example showing the state of unevenness of the rough surface portion of the capacitor C2 is shown in FIG. 2, and that of the capacitor A2 is shown in FIG. As shown in FIG. 2, on the rough surface of the capacitor C2, the area of one concave portion and the area of one convex portion are large, and the concave portion and the convex portion are biased. On the other hand, on the rough surface of the capacitor A2, fine irregularities are uniformly dispersed.
- the present disclosure can be used for solid electrolytic capacitor elements and solid electrolytic capacitors.
- Solid electrolytic capacitor 20 Lead terminal 21: Anode lead terminal 21a, 22a: Embedded portion 21b, 22b: Exposed portion 22: Cathode lead terminal 22a: Embedded portion 22b: Exposed portion 30: Exterior 100: Capacitor element 111: Anode Part 112: Dielectric layer 113: Cathode part 113a: Solid electrolyte layer 113b: Cathode extraction layer p, n: Contact surface
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Abstract
Description
本実施形態に係る固体電解コンデンサは、陽極部と陰極部とを含む少なくとも1つのコンデンサ素子と、前記陽極部に電気的に接続された陽極リード端子と前記陰極部に電気的に接続された陰極リード端子とを含むリード端子と、前記コンデンサ素子を覆う外装体とを含む。前記陽極リード端子および前記陰極リード端子はそれぞれ、前記外装体に埋め込まれた埋め込み部と、前記埋め込み部とつながっており且つ前記外装体から露出している露出部とを含む。陽極リード端子の埋め込み部は、外装体と接触する接触面pを有する。陰極リード端子の埋め込み部は、外装体と接触する接触面nを有する。接触面pおよび前記接触面nから選択される少なくとも一方の接触面は、界面の展開面積比が0.4以上である粗面を有する。界面の展開面積比が0.4以上である粗面を、以下では「粗面(R)」と称する場合がある。界面の展開面積比は、後述する方法で測定できる。
コンデンサ素子(固体電解コンデンサ素子)の構成部材の例について、以下に説明する。本開示に特徴的な部分以外の構成部材には、公知の構成部材を適用してもよい。なお、本開示の効果が得られる限りコンデンサ素子に特に限定はなく、以下で説明するコンデンサ素子以外の他のコンデンサ素子(例えば公知のコンデンサ素子)を用いてもよい。
陽極部は、陽極体を含む。陽極体は、弁作用金属、弁作用金属を含む合金、および弁作用金属を含む化合物などを含むことができる。これらの材料は、一種を単独で使用してもよいし、二種以上を組み合わせて使用してもよい。弁作用金属としては、例えば、アルミニウム、タンタル、ニオブ、チタンが好ましく使用される。表面に多孔質部を備える陽極体は、例えば、弁作用金属を含む金属箔の表面を粗面化することによって得られる。粗面化は、電解エッチング等によって行ってもよい。陽極体全体が多孔質であってもよい。ただし、強度の観点から、陽極体は、両方の主面に配置された多孔質部と、それら多孔質部の間に配置された芯部とを含むことが好ましい。芯部の多孔度は、多孔質部の多孔度よりも低い。多孔質部は、多数の微細な孔を有する領域である。芯部は、例えば、電解エッチングされていない領域である。
コンデンサ素子は、陽極部と陰極部との間に配置された誘電体層を含む。誘電体層は、誘電体として機能する絶縁性の層である。誘電体層は、陽極体(例えば金属箔)の表面の弁作用金属を、陽極酸化することによって形成してもよい。誘電体層は、陽極体(陽極部)の少なくとも一部を覆うように形成されていればよい。誘電体層は、通常、陽極体の表面に形成される。誘電体層は、陽極体の多孔質部の表面に形成されるため、陽極体の表面の孔や窪み(ピットとも称する)の内壁面に沿って形成される。
陰極部は、誘電体層の少なくとも一部を覆う固体電解質層を含み、固体電解質層の少なくとも一部を覆う陰極引出層をさらに含んでもよい。以下、固体電解質層および陰極引出層について以下に説明する。
固体電解質層には、例えば、導電性高分子を含む層を用いることができる。固体電解質層は、必要に応じて、導電性高分子に加えて、ドーパントおよび他の添加剤からなる群より選択される少なくとも一種を含んでもよい。ドーパントとしては、例えば、パラトルエンスルホン酸、ナフタレンスルホン酸、ポリスチレンスルホン酸(PSS)が挙げられるが、これらに限定されるものではない。
陰極引出層には、導電性を有する層を用いることができる。例えば、陰極引出層には、導電性粒子を含む層、金属箔などを用いてもよい。導電性粒子の例には、導電性カーボンおよび金属粒子などが含まれる。陰極引出層は、固体電解質層の側から順に積層された第1の層と第2の層とを含んでもよい。一例では、第1の層に導電性カーボンを含む層を用
い、第2の層に金属粒子を含む層または金属箔を用いてもよい。導電性カーボンの例には、黒鉛(人造黒鉛、天然黒鉛など)などが含まれる。金属粒子の例には、銀粒子などが含まれる。導電性粒子を含む層は、導電性粒子と樹脂(バインダ樹脂)とを含む組成物を用いて形成してもよく、金属ペースト(例えば銀ペースト)を用いても形成してもよい。
本実施形態に係る固体電解コンデンサは、少なくとも1つのコンデンサ素子を含む。固体電解コンデンサに含まれるコンデンサ素子の数は、1~20の範囲(例えば2~10の範囲)にあってもよい。
上述したように、陽極リード端子および陰極リード端子はそれぞれ、埋め込み部と露出部とを含む。陽極リード端子および陰極リード端子は、粗面(R)の部分を除いて公知の材料および公知の方法で形成できる。上述したように、陽極リード端子および陰極リード端子はそれぞれ、金属(銅、銅合金など)からなる金属シート(金属板および金属箔を含む)を加工することによって形成してもよい。すなわち、陽極リード端子および陰極リード端子の基材の材質の例には、銅や銅合金などが含まれる。
本実施形態に係る固体電解コンデンサの製造方法に特に限定はない。それらの製造方法には、粗面(R)を形成する方法を除いて、公知の製造方法を適用してもよいし、公知の製造方法の一部を修正して適用してもよい。
図1は、実施形態1に係る固体電解コンデンサを模式的に示す断面図である。図1に示す固体電解コンデンサ10は、コンデンサ素子100と、リード端子20と、外装体30とを含む。リード端子20は、コンデンサ素子100の陽極部(陽極体)111に電気的に接続された陽極リード端子21と、コンデンサ素子100の陰極部113に電気的に接続された陰極リード端子22とを含む。
以下で説明する方法によって、複数種の固体電解コンデンサを作製した。それぞれの固体電解コンデンサは、1つのコンデンサ素子を含む。固体電解コンデンサおよびコンデンサ素子はそれぞれ、図1に示した固体電解コンデンサ10およびコンデンサ素子100と類似の構造を有する。
20 :リード端子
21 :陽極リード端子
21a、22a :埋め込み部
21b、22b :露出部
22 :陰極リード端子
22a :埋め込み部
22b :露出部
30 :外装体
100 :コンデンサ素子
111 :陽極部
112 :誘電体層
113 :陰極部
113a :固体電解質層
113b :陰極引出層
p、n :接触面
Claims (10)
- 陽極部と陰極部とを含む少なくとも1つのコンデンサ素子と、
前記陽極部に電気的に接続された陽極リード端子と前記陰極部に電気的に接続された陰極リード端子とを含むリード端子と、
前記コンデンサ素子を覆う外装体とを含み、
前記陽極リード端子および前記陰極リード端子はそれぞれ、前記外装体に埋め込まれた埋め込み部と、前記埋め込み部とつながっており且つ前記外装体から露出している露出部とを含み、
前記陽極リード端子の前記埋め込み部は、前記外装体と接触する接触面pを有し、
前記陰極リード端子の前記埋め込み部は、前記外装体と接触する接触面nを有し、
前記接触面pおよび前記接触面nから選択される少なくとも一方の接触面は、界面の展開面積比が0.4以上である粗面を有する、固体電解コンデンサ。 - 前記粗面は、前記露出部の少なくとも一部にも形成されるように、前記埋め込み部から前記露出部にまたがって形成されている、請求項1に記載の固体電解コンデンサ。
- 前記接触面pおよび前記接触面nのそれぞれが前記粗面を有する、請求項1または2に記載の固体電解コンデンサ。
- 前記粗面の界面の展開面積比が10.0以下である、請求項1~3のいずれか1項に記載の固体電解コンデンサ。
- 前記陽極リード端子の基材および前記陰極リード端子の基材から選択される少なくとも一方の基材が銅基材であり、
前記露出部における前記銅基材の少なくとも一部が銅めっき層で被覆されている、請求項1~4のいずれか1項に記載の固体電解コンデンサ。 - 前記銅基材は、前記露出部において前記外装体の外表面に沿って屈曲している屈曲部を有し、
前記屈曲部の外側の表面が前記銅めっき層で被覆されている、請求項5に記載の固体電解コンデンサ。 - 前記銅めっき層を覆う錫めっき層をさらに含む、請求項5または6に記載の固体電解コンデンサ。
- 前記銅めっき層と前記錫めっき層との間に配置された他の層をさらに含み、
前記他の層は、銅と錫との合金層またはニッケルめっき層である、請求項7に記載の固体電解コンデンサ。 - 前記銅めっき層を覆う貴金属めっき層をさらに含み、
前記貴金属めっき層は、金、白金、およびパラジウムからなる群より選択される少なくとも1種を含む、請求項5または6に記載の固体電解コンデンサ。 - 前記銅めっき層と前記貴金属めっき層との間に配置されたニッケルめっき層をさらに含む、請求項9に記載の固体電解コンデンサ。
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH02239608A (ja) * | 1989-03-13 | 1990-09-21 | Hitachi Cable Ltd | コンデンサ用リードフレーム |
JPH11283870A (ja) * | 1998-03-27 | 1999-10-15 | Sanyo Electric Co Ltd | チップ状電子部品 |
JP2000049056A (ja) * | 1998-05-27 | 2000-02-18 | Matsushita Electric Ind Co Ltd | 固体電解コンデンサ |
JP2000340463A (ja) * | 2000-01-01 | 2000-12-08 | Matsushita Electric Ind Co Ltd | 固体電解コンデンサ |
JP2020053588A (ja) * | 2018-09-27 | 2020-04-02 | 株式会社村田製作所 | 固体電解コンデンサ |
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Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH02239608A (ja) * | 1989-03-13 | 1990-09-21 | Hitachi Cable Ltd | コンデンサ用リードフレーム |
JPH11283870A (ja) * | 1998-03-27 | 1999-10-15 | Sanyo Electric Co Ltd | チップ状電子部品 |
JP2000049056A (ja) * | 1998-05-27 | 2000-02-18 | Matsushita Electric Ind Co Ltd | 固体電解コンデンサ |
JP2000340463A (ja) * | 2000-01-01 | 2000-12-08 | Matsushita Electric Ind Co Ltd | 固体電解コンデンサ |
JP2020053588A (ja) * | 2018-09-27 | 2020-04-02 | 株式会社村田製作所 | 固体電解コンデンサ |
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