Solid electrolytic capacitor and method of manufacture
View Patent ↗An improved solid electrolytic capacitor and method of forming a solid electrolytic capacitor is described. The method includes forming an anode comprising a valve metal or conductive oxide of a valve metal wherein an anode lead extension protrudes from the anode. A dielectric is formed on the anode and a cathode layer is formed on the dielectric. The anode, dielectric, and cathode layer are encased in a non-conducting material and the anode lead extension is exposed outside of the encasement at a side surface. A conductive metal layer is adhered to the anode lead extension which allows termination preferably by electrically connecting a preformed solid metal terminal, most preferably an L shaped terminal, to the conductive metal layer at the side surface.
1. A method of forming a solid electrolytic capacitor comprising:
forming an anode comprising a valve metal or conductive oxide of a valve metal wherein an anode lead extension protrudes from said anode;
forming a dielectric on said anode;
forming a cathode layer on said dielectric;
encasing said anode, said dielectric, and said cathode layer in a non-conducting material encasement;
exposing said anode lead extension outside of said encasement at a side surface;
adhering a conductive metal layer to said anode lead extension; and
electrically connecting a preformed solid metal terminal to said conductive metal layer at said side surface.
2. The method of forming a solid electrolytic capacitor of claim 1 wherein said preformed solid metal terminal is L shaped with a width which is at least 0.4 mm less than the maximum width of said encasement.
3. The method of forming a solid electrolytic capacitor of claim 2 wherein said L shaped preformed solid metal terminal is applied to a bottom face of said capacitor.
4. The method of forming a solid electrolytic capacitor of claim 3 wherein a portion of said L shaped preformed solid metal terminal is adhered to said encasement with an adhesive.
5. The method for forming a capacitor of claim 3 wherein said first face and said second face are on opposing sides of said encasement and said anode terminal and cathode terminal are symmetric.
6. The method of forming a solid electrolytic capacitor of claim 1 wherein said anode lead extension is a valve metal or a conductive oxide of a valve metal.
7. The method of forming a solid electrolytic capacitor of claim 1 wherein said adhering is by a method selected from metal flame spray, chemical vapor deposition, metal sputtering, electroplating, electroless plating and powder metal sintering.
8. The method of forming a solid electrolytic capacitor of claim 1 further comprising zincating said anode lead extension prior to said adhering.
9. The method of forming a solid electrolytic capacitor of claim 8 wherein said conductive metal layer is nickel.
10. The method of forming a solid electrolytic capacitor of claim 1 wherein said electrically connecting comprises a method selected from soldering, conductive adhesive bonding, brazing, nano foil bonding, ultrasonic welding, laser welding, resistance welding and low temperature sintering.
11. The method of forming a solid electrolytic capacitor of claim 1 wherein said cathode layer comprises an intrinsically conductive polymer.