Solid electrolytic capacitor, and method of manufacturing same

Claim 2

A solid electrolytic capacitor characterized by having a capacitor element comprising: a metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer of a desired shape formed on a predetermined portion of said metal plate; a dielectric oxidation layer formed on a surface of said metal plate at one portion thereof defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said polymer layer; a first terminal attached to another portion of said metal plate defined by said insulator layer; and a second terminal attached to said conductive layer.

Claim 3

The solid electrolytic capacitor according to claim 1, wherein said metal plate is selected from the group consisting of an aluminum thin plate, a tantalum thin plate, a niobium thin plate and a titanium thin plate.

Claim 4

The solid electrolytic capacitor according to claim 1, wherein said polymer layer is a polypyrrole layer formed by electrochemical polymerization in an electrolyte solution containing pyrrole and a supporting electrolyte.

Claim 5

The solid electrolytic capacitor according to claim 1, wherein said conductive layer comprises a graphite layer and a silver paste layer.

Claim 6

The solid electrolytic capacitor according to claim 1, wherein said conductive layer comprises a graphite layer and a silver paste layer, and said silver paste layer laminated portions are integrated by application of pressure and hardening.

Claim 9

The method according to claim 6, wherein said polymer layer is a polypyrrole layer and said polypyrrole layer is formed by electrochemical polymerization in an electrolyte solution containing pyrrole, borodisalycylic acid or borodisalicylate.

Claim 10

The method according claim 6, wherein at least one of the terminal spacing and terminal extraction direction is freely adjusted by changing a position at which the insulator layer is formed on each of said projections and the shape of the insulator layer.

Claim 11

The method according to claim 6 or 8, wherein said projections are formed on both side edges of the strip-shaped metal plate.

Claim 12

A solid electrolytic capacitor characterized by having a multilayer capacitor element comprising: a plurality of metal plates capable of having a dielectric oxidation layer formed thereon; an insulator layer of a desired shape formed on a first portion of said metal plates; a dielectric oxidation layer formed on a surface of said metal plates at the first portion thereof defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said polymer layer; the plurality of said metal plates being stacked into a laminate in such a manner that the first portions defined by said insulator layer are made to correspond and second portions defined by said insulator layer are made to correspond; said laminate being integrated by application of pressure thereto, and said metal plates at the second portions defined by said insulator layers of said laminate being joined; a first terminal attached to another portion of said metal plate defined by said insulator layer; and a second terminal attached to said conductive layer.

Claim 13

A solid electrolytic capacitor characterized by having a multilayer capacitor element comprising: a plurality of metal plates capable of having a dielectric oxidation layer formed thereon; an insulator layer of a desired shape formed on a first portion of said metal plates; a dielectric oxidation layer formed on a surface of said metal plates at the first portion thereof defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said polymer layer; the plurality of said metal plates being stacked into a laminate in such a manner that the first portions defined by said insulator layer are made to correspond and second portions defined by said insulator layer are made to correspond; said laminate being integrated by application of pressure thereto, and said metal plates at the second portions defined by said insulator layers of said laminate being joined; a first terminal attached to another portion of said metal plate defined by said insulator layer; and a second terminal attached to said conductive layer.

Claim 14

A solid electrolytic capacitor characterized by having a capacitor element comprising: a plurality of metal plates capable of having a dielectric oxidation layer formed thereon; an insulator layer of a desired shape formed on a first portion of said metal plates; a dielectric oxidation layer formed on a surface of said metal plates at the first portion thereof defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boron acid and any of the compounds (1) to (4); a conductive layer formed on said polymer layer; the plurality of said metal plates being stacked into a laminate in such a manner that the first portions defined by said insulator layer are made to correspond and second portions defined by said insulator layer are made to correspond, with conductive plates being interposed between said first portions; said second portions defined by said insulator layers being joined to one another and said conductive plates being joined to one another to form joints; and terminals attached to the respective joints.

Claim 15

A solid electrolytic capacitor characterized by having a capacitor element comprising: a plurality of metal plates capable of having a dielectric oxidation layer formed thereon; an insulator layer of a desired shape formed on a first portion of said metal plates; a dielectric oxidation layer formed on a surface of said metal plates at the first portion thereof defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boron acid and any of the compounds (1) to (4); a conductive layer formed on said polymer layer; the plurality of said metal plates being stacked into a laminate in such a manner that the first portions defined by said insulator layer are made to correspond and second portions defined by said insulator layer are made to correspond, with conductive plates being interposed between said first portions; said second portions defined by said insulator layers being joined to one another and said conductive plates being joined to one another to form joints; and terminals attached to the respective joints.

Claim 16

The solid electrolytic capacitor according to claim 10 or 11, wherein said metal plate is selected from the group consisting of an aluminum thin plate, a tantalum thin plate, a niobium thin plate and a titanium thin plate.

Claim 17

The solid electrolytic capacitor according to claim 11, wherein said conductive layer comprises a graphite layer and a silver paste layer, said conductive plates are interposed between said silver paste layers, and said silver paste layers and conductive plates are stacked and integrated by application of pressure and hardening.

Claim 18

The solid electrolytic capacitor according to claim 11, wherein said conductive plate comprises a thin plate of copper.

Claim 19

The solid electrolytic capacitor according to claim 10 or 11, wherein distal ends of said terminals are extended to a bottom portion of a housing to form the capacitor into a chip-type capacitor.

Claim 20

The solid electrolytic capacitor according to claim 10 or 11, wherein said terminals are extended to an external portion of a housing to form the capacitor into a lead terminal-type capacitor.

Claim 21

The solid electrolytic capacitor according to claim 10 or 11, wherein said terminals are extended to an external portion of a housing from both sides thereof to form the capacitor into a four terminal-type capacitor.

Claim 24

The method according to claim 18, wherein said steps of applying pressure to and integrating the projections of said laminate comprises the steps of hardening said silver paste layers and joining and integrating said projections of said laminate.

Claim 27

The method according to claim 18 or 20, wherein said metal plate is strip-shaped and said projections are formed on one or both side edges thereof.

Claim 28

The method according to claim 18 or 20, wherein said step of forming the polymer layer comprises the step of forming a polypyrrole layer by carrying out electrochemical polymerization in an electrolyte solution containing pyrrole and a supporting electrolyte.

Claim 29

The method according to claim 18 or 20, wherein said step of forming the conductive layer comprises: dipping said metal plate in a graphite solution and hardening to form a graphite layer, and dipping said metal plate in a silver paste solution and hardening to form said silver paste layer.

Claim 30

The method according to claim 20, wherein said steps of applying pressure to and integrating the projections of said laminate comprises the steps of hardening said silver paste layers and joining and integrating said silver paste layers and said conductive plates.

Claim 31

A solid electrolytic capacitor characterized by having an array-type electrolytic capacitor element comprising: a metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer formed on said metal plate; a plurality of metal exposing surfaces defined on said metal plate by said insulator layer, each metal exposing surface being continuous from an obverse side to reverse side of said metal plate; a dielectric oxidation layer formed on all but at least one of said plurality of metal exposing surfaces; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said conductive polymer layer; a first terminal provided on the at least one of said metal exposing surfaces not having said dielectric oxidation layer formed thereon; and second terminals provided on said conductive layer formed on respective ones of said metal exposing surfaces.

Claim 32

A solid electrolytic capacitor characterized by having an array-type electrolytic capacitor element comprising: a metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer formed on said metal plate; a plurality of metal exposing surfaces defined on said metal plate by said insulator layer, each metal exposing surface being continuous from an obverse side to reverse side of said metal plate; a dielectric oxidation layer formed on all but at least one of said plurality of metal exposing surfaces; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said conductive polymer layer; a first terminal provided on the at least one of said metal exposing surfaces not having said dielectric oxidation layer formed thereon; and second terminals provided on said conductive layer formed on respective ones of said metal exposing surfaces.

Claim 33

The solid electrolytic capacitor according to claim 25, wherein said metal plate is selected from the group consisting of an aluminum plate, a tantalum plate, a niobium plate and a titanium plate.

Claim 34

The solid electrolytic capacitor according to claim 25, wherein said polymer layer is a polypyrrole layer formed by electrochemical polymerization in an electrolyte solution containing pyrrole and a supporting electrolyte.

Claim 35

The solid electrolytic capacitor according to claim 25, wherein said conductive layer comprises a graphite layer and a silver paste layer.

Claim 36

The solid electrolytic capacitor according to claim 25, wherein a resin molded cladding is formed on said array-type solid electrolytic capacitor element.

Claim 37

A solid electrolytic capacitor having a multilayer array-type solid electrolytic capacitor element comprising: a metal plate formed to include a variety of projections of a predetermined shape on at least one side edge thereof, said metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer formed on a predetermined portion of each of said projections; a dielectric oxidation layer formed on the surface of the tip of each of said projections defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a ploymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said conductive polymer layer; a plurality of said metal plates being stacked in such a manner that the projections thereof are made to correspond to on another, said stacked plates being integrated by application of pressure thereto; a first terminal provided on said stacked metal plates; and a second terminals provided on said conductive layer formed on the tip ends of said projection defined by said insulator layers on said projections.

Claim 38

A solid electrolytic capacitor having a multilayer array-type solid electrolytic capacitor element comprising: a metal plate formed to include a variety of projections of a predetermined shape on at least one side edge thereof, said metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer formed on a predetermined portion of each of said projections; a dielectric oxidation layer formed on the surface of the tip of each of said projections defined by said insulator layer; a conductive polymer layer formed on said dielectric oxidation layer which is a ploymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said conductive polymer layer; a plurality of said metal plates being stacked in such a manner that the projections thereof are made to correspond to on another, said stacked plates being integrated by application of pressure thereto; a first terminal provided on said stacked metal plates; and a second terminals provided on said conductive layer formed on the tip ends of said projection defined by said insulator layers on said projections.

Claim 39

The solid electrolytic capacitor according to claim 30, wherein said metal plate is selected from the group consisting of an aluminum plate, a tantalum plate, a niobium plate and a titanium plate.

Claim 40

The solid electrolytic capacitor according to claim 30, wherein said polymer layer is a polypyrrole layer formed by electrochemical polymerization in an electrolyte solution containing pyrrole and a supporting electrolyte.

Claim 41

The solid electrolytic capacitor according to claim 30, wherein said conductive layer comprises a graphite layer and a silver paste layer.

Claim 42

A solid electrolytic capacitor having a multilayer array-type solid electrolytic capacitor element comprising: a metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer formed on said metal plate; a plurality of metal exposing surfaces defined on said metal plate by the insulator layer, each metal exposing surface having the same shape and being continuous from an obverse side to a reverse side of said metal plate; a dielectric oxidation layer formed on all but at least one of said plurality of metal exposing surfaces; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said conductive polymer layer; a plurality of said metal plates being stacked in such a manner that the conductive layers thereof are made to correspond to one another, said stacked plates being integrated by application of pressure thereto; a first terminal provided on the at least one of said metal exposing surfaces of said stacked metal plates not having a dielectric oxidation layer formed thereon; and a second terminals provided on the surface of the conductive layers, or provided between these conductive layers, formed on respective ones of said metal exposing surfaces of the stacked metal plates.

Claim 43

A solid electrolytic capacitor having a multilayer array-type solid electrolytic capacitor element comprising: a metal plate capable of having a dielectric oxidation layer formed thereon; an insulator layer formed on said metal plate; a plurality of metal exposing surfaces defined on said metal plate by the insulator layer, each metal exposing surface having the same shape and being continuous from an obverse side to a reverse side of said metal plate; a dielectric oxidation layer formed on all but at least one of said plurality of metal exposing surfaces; a conductive polymer layer formed on said dielectric oxidation layer which is a polymer layer of a heterocyclic compound selected from the group consisting of pyrrole, furan and thiopene formed by electrochemical polymerization in an electrolyte solution containing said heterocyclic compound and supporting electrolyte which either comprises boric acid and any one of the following organic compounds: (1) an aliphatic or aromatic carboxylic acid, or a salt thereof; (2) an aliphatic or aromatic compound having two or more carbonyl radicals, or a salt thereof; (3) an aliphatic or aromatic compound having at least one hydroxyl radical and at least one carboxylic radical, or a salt thereof; and (4) an aliphatic or aromatic compound having at least one amine radical and at least one carboxylic radical, or a salt thereof; or comprises a boron compound obtained by chemically combining boric acid and any of the compounds (1) to (4); a conductive layer formed on said conductive polymer layer; a plurality of said metal plates being stacked in such a manner that the conductive layers thereof are made to correspond to one another, said stacked plates being integrated by application of pressure thereto; a first terminal provided on the at least one of said metal exposing surfaces of said stacked metal plates not having a dielectric oxidation layer formed thereon; and a second terminals provided on the surface of the conductive layers, or provided between these conductive layers, formed on respective ones of said metal exposing surfaces of the stacked metal plates.

Claim 44

The solid electrolytic capacitor according to claim 34, wherein said metal plate is selected from the group consisting of an aluminum plate, a tantalum plate, a niobium plate and a titanium plate.

Claim 45

The solid electrolytic capacitor according to claim 34, wherein said polymer layer is a polypyrrole layer formed by electrochemical polymerization in an electrolyte solution containing pyrrole and a supporting electrolyte.

Claim 46

The solid electrolytic capacitor according to claim 34, wherein said conductive layer comprises a graphite layer and a silver paste layer.