Solid electrolytic capacitor and method of producing the same

1. A solid electrolytic capacitor comprising:

a lead wire;

an anode member by comprising a sintered member of a valve-action metal powder having the lead wire embedded therein;

a dielectric layer formed on a surface of the anode member;

a first electrolyte element in an electrolyte layer formed on the dielectric layer and defining a plurality of cavities;

non-conductive particles dispersed in the cavities defined by the first electrolyte element;

a second electrolyte element provided in the electrolyte layer so as to surround the non-conductive particles;

a cathode member formed on the first electrolyte layer such that particles of a material of the cathode member are dispersed in the electrolyte layer;

a silver paste layer formed on the cathode member;

external terminals respectively connected to the lead wire and the silver paste layer; and

a resin package molded so as to expose the external terminals.

2. The solid electrolytic capacitor according to claim 1 , wherein said non-conductive particles have an average size which is smaller than an average size of the particles of the material of said cathode member.

3. The solid electrolytic capacitor according to claim 1 , wherein said valve action metal is one of Nb, Al, Ta, Ti, Hf and Zr.

4. The solid electrolytic capacitor according to claim 1 , wherein said first electrolyte element includes at least one of a conductive polymer formed by polymerizing pyrrole and a conductive polymer formed by polymerizing thiophene.

5. The solid electrolytic capacitor according to claim 4 , wherein said electrolyte layer includes a conductive powder comprising at least one of SnO 2 powder, ZnO powder, and a carbon-based conductive filler comprising at least one of carbon black, graphite and carbon fibers.

6. The solid electrolytic capacitor according to claim 5 , wherein said conductive powder comprises the at least one of the SnO 2 powder and the ZnO powder covering at least one of TiO 2 and a BaSO 4 .

7. The solid electrolytic capacitor according to claim 4 , wherein said electrolyte layer includes a carbon-based conductive filler comprising at least one of carbon black, graphite and carbon fibers.

8. The solid electrolytic capacitor according to claim 1 , wherein said second electrolyte element comprises a conductive polymer which surrounds the non-conductive particles, and wherein said second electrolyte element is provided between (i) a surface of at least one of said dielectric layer and said cathode member, and (ii) the particles of the material of the cathode member which are dispersed in the electrolyte layer.

9. A The solid electrolytic capacitor according to claim 1 , wherein said cathode member comprises graphite.

10. A solid electrolytic capacitor comprising:

a lead wire;

an anode member comprising a sintered member of a valve-action metal powder having the lead wire embedded therein;

a dielectric layer formed on a surface of the anode member;

a first electrolyte element in an electrolyte layer formed on the dielectric layer and defining a plurality of cavities;

non-conductive particles dispersed in the cavities defined by the first electrolyte element;

a second electrolyte element provided in the electrolyte layer so as to surround the non-conductive particles;

a cathode member formed on the electrolyte layer such that particles of a material of the cathode member are dispersed in the electrolyte layer;

a silver paste layer formed on the cathode member; and

external terminals respectively connected to the lead wire and the silver paste layer;

wherein the non-conductive particles are also positioned in an area defined by a recess in the dielectric layer, and said second electrolyte element is provided in the electrolyte layer after said non-conductive particles are positioned in the area defined by the recess in said dielectric layer.

11. The solid electrolytic capacitor according to claim 10 , wherein said non-conductive particles are also positioned on a surface of said dielectric layer, and said second electrolyte element is provided so as to prevent said cathode member from contacting said non-conductive particles.

12. A solid electrolytic capacitor comprising:

a lead wire;

an anode member comprising a sintered member of a valve-action metal powder having the lead wire embedded therein;

a dielectric layer formed on a surface of the anode member;

a first electrolyte element in an electrolyte layer formed on the dielectric layer and defining a plurality of cavities;

non-conductive particles dispersed in the cavities defined by the first electrolyte element;

a second electrolyte element provided in the electrolyte layer so as to surround the non-conductive particles;

a cathode member formed on the electrolyte layer such that particles of a material of the cathode member are dispersed in the electrolyte layer;

a silver paste layer formed on the cathode member; and external terminals respectively connected to the lead wire and the silver paste layer;

wherein said second electrolyte element is provided in the electrolyte layer after said non-conductive particles are positioned; and

wherein a distance from an interface between said electrolyte layer and said dielectric layer to a surface of said anode member is smaller than an average thickness of said electrolyte layer.

13. The solid electrolytic capacitor according to claim 12 , wherein said non-conductive particles are also positioned on a surface of said dielectric layer, and said second electrolyte element is provided so as to prevent said cathode member from contacting said non-conductive particles.

14. A method of producing a solid electrolytic capacitor, said method comprising:

sintering a valve-action metal powder while embedding a lead wire therein to form an anode member;

forming a dielectric layer on a surface of said anode member;

forming an electrolyte layer, including a first electrolyte element, on said dielectric layer of said anode member;

immersing said anode member having the electrolyte layer formed thereon in a colloid solution in which non-conductive colloid particles are dispersed, and then drying said anode member;

providing a second electrolyte element in the electrolyte layer;

forming a cathode member so as to sandwich said electrolyte layer between said cathode layer and said dielectric layer,

forming a silver paste layer on said cathode member, and

connecting external terminals respectively with said lead wire and said silver paste layer and applying a resin mold so as to expose said external terminals.

15. The method according to claim 14 , wherein said immersion of the anode member in the colloid solution causes the non-conductive particles to be present between said dielectric layer and said first electrolyte element.

16. The method according to claim 14 , wherein said immersion of the anode member in the colloid solution causes the non-conductive particles to be present in an area defined by a recess on a surface of said dielectric layer.

17. The method according to claim 14 , wherein said immersion is carried out under a pressure such that the non-conductive particles are present in an area on a surface of said dielectric layer where a distance from an interface between said first electrolyte layer and said dielectric layer to a surface of said anode member is smaller than an average thickness of said dielectric layer.

18. The method according to claim 14 , wherein said non-conductive particles have an average size which is smaller than an average size of particles of a material of said cathode member.

19. The method according to claim 14 , wherein at least one of said first electrolyte element and said second electrolyte element comprise at least one of a conductive polymer polymerized from pyrrole, and a conductive polymer polymerized from thiophene.