High voltage solid electrolytic capacitors using conductive polymer slurries
View Patent ↗A method for forming a capacitor including forming an anode from a valve metal; forming an oxide on the anode to form an anodized anode; dipping the anodized anode into a slurry of conductive polymer; drying the intrinsically conductive polymer; and providing external terminations in electrical contact with the anode and the conductive polymer.
1. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer;
providing terminations in electrical contact with said anode and said intrinsically conductive polymer; and wherein said capacitor has a breakdown voltage of at least 60V wherein said capacitor has a breakdown voltage to formation voltage ratio of at least 0.46.
2. The capacitor of claim 1 wherein said capacitor has a breakdown voltage to formation voltage ratio of at least 0.54.
3. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer;
providing terminations in electrical contact with said anode and said intrinsically conductive polymer; and wherein said capacitor has a breakdown voltage of at least 60V wherein said capacitor has an anode with a volumetric efficiency of at least 555 μF/cc.
4. The capacitor of claim 3 wherein said capacitor has an anode wherein the product of volumetric efficiency and break down voltage is at least 33,300 V·μF/cc.
5. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer;
providing terminations in electrical contact with said anode and said intrinsically conductive polymer;
prior to said dipping processing said dielectric coated anode in at least one in-situ polymerization cycle wherein said capacitor has a breakdown voltage of at least 60V wherein said capacitor has a breakdown voltage to formation voltage ratio of at least 0.46.
6. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer;
providing terminations in electrical contact with said anode and said intrinsically conductive polymer;
prior to said dipping processing said dielectric coated anode in at least one in-situ polymerization cycle wherein said capacitor has a breakdown voltage of at least 60V wherein said capacitor has a breakdown voltage to formation voltage ratio of at least 0.54.
7. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer;
providing terminations in electrical contact with said anode and said intrinsically conductive polymer;
prior to said dipping processing said dielectric coated anode in at least one in-situ polymerization cycle wherein said capacitor has a breakdown voltage of at least 60V wherein said capacitor has an anode with a volumetric efficiency of at least 555 μF/cc.
8. The capacitor of claim 7 wherein said capacitor has an anode wherein the product of volumetric efficiency and break down voltage is at least 33,300 V·μF/cc.
9. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer; and
providing terminations in electrical contact with said anode and said intrinsically conductive polymer wherein said capacitor has a breakdown voltage from 60V to 120V wherein said capacitor has a breakdown voltage to formation voltage ratio of at least 0.46.
10. The capacitor of claim 9 wherein said capacitor has a breakdown voltage to formation voltage ratio of at least 0.54.
11. A capacitor formed by the method of:
forming an anode from a valve metal;
forming a dielectric layer on said anode to form a dielectric coated anode;
coating said dielectric coated anode with a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer; and
providing terminations in electrical contact with said anode and said intrinsically conductive polymer wherein said capacitor has a breakdown voltage from 60V to 120V wherein said capacitor has an anode with a volumetric efficiency of at least 555 μF/cc.
12. The capacitor of claim 11 wherein said capacitor has an anode wherein the product of volumetric efficiency and break down voltage is at least 33,300 V·μF/cc.
13. A capacitor formed by the method of:
forming an anode from a valve metal selected from tantalum and niobium;
forming a dielectric layer on said anode to form a dielectric coated anode;
dipping said dielectric coated anode into a slurry of intrinsically conductive polymer;
drying said intrinsically conductive polymer;
providing terminations in electrical contact with said anode and said intrinsically conductive polymer; and wherein said capacitor has a breakdown voltage of at least 60V, and a breakdown voltage to formation voltage ratio of at least 0.46 and said anode has a product of volumetric efficiency and break down voltage which is at least 33,300 V·μF/cc.
14. The capacitor of claim 13 wherein said breakdown voltage to formation voltage ratio is at least 0.54.