Solid electrolytic capacitor having a high capacitance
A solid electrolytic capacitor that comprises an anode that comprises a porous anode body and a dielectric layer is provided. The anode body is formed from a pressed and sintered valve metal powder having a specific charge of about 200,000 μF*V/g or more and a phosphorous content of about 150 parts per million or less. A solid electrolyte overlies the anode.
1. A solid electrolytic capacitor comprising: an anode that comprises a porous anode body and a dielectric layer, wherein the anode body is formed from a pressed and sintered valve metal powder having a specific charge of about 200,000 pF*V/g or more and a phosphorous content of about 150 parts per million or less; and a solid electrolyte overlying the anode wherein the capacitor exhibits a dissipation factor of about 65% or less, as determined at a frequency of 120 Hz; wherein the powder contains primary particles having a median size of from about 5 to about 250 nanometers; wherein the primary particles have an aspect ratio of about 4 or less; and
wherein the primary particles have a granular, angular or nodular shape.
2. The solid electrolytic capacitor of claim 1 , wherein the valve metal powder includes tantalum.
3. The solid electrolytic capacitor of claim 1 , wherein the powder is formed by reacting a tantalum salt with a reducing agent.
4. The solid electrolytic capacitor of claim 3 , wherein the reducing agent is hydrogen gas.
5. The solid electrolytic capacitor of claim 1 , wherein the powder is formed from agglomerated particles.
6. The solid electrolytic capacitor of claim 1 , wherein an anode lead is be connected to the anode body.
7. The solid electrolytic capacitor of claim 1 , further comprising:
an anode termination that is in electrical connection with the anode lead;
a cathode termination that is in electrical connection with the solid electrolyte; and
a casing that encapsulates the capacitor anode and the solid electrolyte and leaves exposed at least a portion of the anode termination and the cathode termination.
8. The solid electrolytic capacitor of claim 1 , wherein the solid electrolyte includes a conductive polymer.
9. The solid electrolytic capacitor of claim 8 , wherein the conductive polymer is poly(3,4-ethylenedioxythiophene) or a derivative thereof.
10. The solid electrolytic capacitor of claim 1 , wherein the solid electrolyte includes manganese dioxide.
11. The solid electrolytic capacitor of claim 1 , wherein the capacitor exhibits a wet-to-dry capacitance percentage of about 75% or more, as determined at a frequency of 120 Hz.
12. The solid electrolytic capacitor of claim 1 , wherein the capacitor exhibits an ESR of from about 0.05 to about 2.0 ohms, as determined at a frequency of 100 kHz.
13. The solid electrolytic capacitor of claim 1 , wherein the capacitor exhibits a leakage current of about 75 microamps or less, as determined at a voltage of 6.3 V per 60 seconds.
14. The solid electrolytic capacitor of claim 1 , wherein the powder has a phosphorous content of about 50 parts per million or less.
15. A method of forming a solid electrolytic capacitor, the method comprising: pressing a valve metal powder into an anode body, wherein the powder has a specific charge of about 200,000 pF*V/g or more and a phosphorous content of about 150 parts per million or less, wherein the powder contains primary particles having a median size of from about 5 to about 250 nanometers; the primary particles have an aspect ratio of about 4 or less; and the primary particles have a granular, angular or nodular shape; sintering the anode body; forming a dielectric layer over the sintered anode body; applying a solid electrolyte over the dielectric layer; and wherein the capacitor exhibits a dissipation factor of about 65% or less, as determined at a frequency of 120 Hz.
16. The method of claim 15 , wherein the valve metal powder includes tantalum.
17. The method of claim 15 , wherein the powder is formed by reacting a tantalum salt with a reducing agent.
18. The method of claim 17 , wherein the reducing agent is hydrogen gas.
19. The method of claim 15 , wherein the powder is agglomerated at a temperature of from about 0° C. to about 40° C. in the presence of a binder.
20. The method of claim 15 , wherein the solid electrolyte includes a conductive polymer.
21. The method of claim 20 , wherein the conductive polymer is poly(3,4-ethylenedioxythiophene) or a derivative thereof.
22. The method of claim 15 , wherein the solid electrolyte includes manganese dioxide.