Methods for producing electrolytic capacitors having a polymeric intermediate layer, capacitors produced thereby and uses thereof

1. A method of producing an electrolytic capacitor, the method comprising:

(i) providing a capacitor body comprising a porous electrode, a dielectric disposed on a surface of the porous electrode, and a solid electrolyte comprising an electrically conductive material covering at least a portion of the dielectric;

(ii) applying a first dispersion (a 1 ) comprising at least particles (b 1 ) of an electrically conductive polymer having an average diameter of 1-60 nm, a binder (c 1 ) and a dispersing agent (d 1 ) to the capacitor body, and at least partially removing the dispersing agent (d 1 ) to form an electrically conductive polymeric intermediate layer on the capacitor body, wherein the solids content of the polymeric binder (c 1 ) in dispersion (a 1 ) is 0.5 to 30% by weight; and

(iii) applying a second dispersion (a 2 ) comprising at least particles (b 2 ) of an electrically conductive polymer having an average diameter of 100-600 nm, a binder (c 2 ), and a dispersing agent (d 2 ), and at least partially removing the dispersing agent (d 2 ), curing the binder (c 2 ) or both, to form an electrically conductive polymeric outer layer;

wherein the particles of the electrically conductive polymer in the first and the second dispersion comprise a polythiophene/polyanion complex.

2. The method according to claim 1 , wherein one or both of the electrically conductive polymeric intermediate layer and the electrically conductive polymeric outer layer has a specific electrical conductivity of greater than 10 S/cm.

3. The method according to claim 1 , wherein one or both of the dispersion (a 1 ) and the dispersion (a 2 ) has a metals content of less than 5,000 mg/kg.

4. The method according to claim 1 , wherein one or both of the binder (c 1 ) and the binder (c 2 ) each independently comprises a polymeric organic binder.

5. The method according to claim 1 , wherein one or both of the dispersing agent (d 1 ) and the dispersing agent (d 2 ) each independently comprises a component selected from the group consisting of organic solvents, water and mixtures thereof.

6. The method according to claim 1 , wherein one or both of the electrically conductive polymer of particles (b 1 ) and the electrically conductive polymer of the particles (b 2 ) each independently comprises at least one polythiophene having one or more repeating units selected from the group consisting of general formula (I), general formula (II), general formula (X) and combinations thereof,

wherein each A independently represents an optionally substituted C 1 -C 5 alkylene radical, each R independently represents an H, a linear or branched, optionally substituted C 1 -C 18 alkyl radical, an optionally substituted C 5 -C 12 cycloalkyl radical, an optionally substituted C 6 -C 14 aryl radical, an optionally substituted C 7 -C 18 aralkyl radical, an optionally substituted C 1 -C 4 hydroxyalkyl radical or a hydroxyl radical, and x represents an integer from 0 to 8.

7. The method according to claim 1 , wherein one or both of the electrically conductive polymer of particles (b 1 ) and the electrically conductive polymer of the particles (b 2 ) each independently comprises an optionally substituted poly(3,4-ethylenedioxythiophene).

8. The method according to claim 1 , wherein one or both of the dispersion (a 1 ) and the dispersion (a 2 ) each independently further comprises at least one polymeric anion selected from the group consisting of anions of polymeric carboxylic or sulphonic acids.

9. The method according to claim 1 , wherein one or both of the dispersion (a 1 ) and the dispersion (a 2 ) each independently further comprises a crosslinking agent(s) and/or a surface-active substance(s) and/or a further additive(s).

10. The method according to claim 1 , wherein one or both of applying the dispersion (a 1 ) and applying the dispersion (a 2 ) is repeated one or more times.

11. The method according to claim 1 , wherein the solid electrolyte comprises a conductive polymer.

12. A method of producing an electrolytic capacitor, the method comprising:

(i) providing a capacitor body comprising a porous electrode, a dielectric disposed on a surface of the porous electrode, and a solid electrolyte comprising an electrically conductive material covering at least a portion of the dielectric;

(ii) applying a first dispersion (a 1 ) comprising at least particles (b 1 ) of an electrically conductive polymer having an average diameter of 1-60 nm, a binder (c 1 ) and a dispersing agent (d 1 ) to the capacitor body, and at least partially removing the dispersing agent (d 1 ) to form an electrically conductive polymeric intermediate layer on the capacitor body, wheren the solids content of the polymeric binder (c 1 ) in dispersion (a 1 ) is 0.5 to 30% by weight; and

(iii) applying a second dispersion (a 2 ) comprising at least particles (b 2 ) of an electrically conductive polymer having an average diameter of 100-600 nm, a binder (c 2 ), and a dispersing agent (d 2 ), and at least partially removing the dispersing agent (d 2 ), curing the binder (c 2 ) or both, to form an electrically conductive polymeric outer layer;

wherein the particles of the electrically conductive polymer in the first and the second dispersion comprise a polythiophene/polyanion complex,

wherein the solid electrolyte comprises a poly(3,4-ethylenedioxythiophene)/polystyrene sulphonic acid.

13. The method according to claim 1 , wherein the porous electrode comprises a valve metal or a compound having the electrical properties of a valve metal.

14. An electrolytic capacitor produced by the method according to claim 1 .

15. An electronic circuit comprising an electrolytic capacitor according to claim 14 .