Low ESR anode lead tape for a solid electrolytic capacitor

1. A solid electrolytic capacitor, the solid electrolytic capacitor comprising:

a capacitor element, wherein the capacitor element comprises a sintered, porous anode body; a dielectric layer overlying the sintered, porous anode body; and a cathode overlying the dielectric layer that includes a solid electrolyte; and

an anode lead assembly, wherein the anode lead assembly comprises an anode lead tape having an embedded portion positioned within the sintered, porous anode body and an external portion extending from a surface of the sintered, porous anode body in a longitudinal direction, wherein the anode lead tape has a width and a height, wherein the ratio of the width of the anode lead tape to the height of the anode lead tape is from about 1.5 to about 10; and a carrier lead wire positioned external to the sintered, porous anode body, wherein the carrier lead wire comprises a first portion and a second portion, wherein the first portion has a width that is greater than a diameter of the second portion, wherein the first portion has a substantially planar surface, wherein the substantially planar surface of the first portion of the carrier lead wire is connected to the external portion of the anode lead tape, and wherein the width of the first portion of the carrier lead wire is smaller than the width of the anode lead tape.

2. The solid electrolytic capacitor of claim 1 , wherein the sintered, porous anode body has a width, wherein the width of the anode lead tape is from about 25% to about 85% of the width of the sintered, porous anode body.

3. The solid electrolytic capacitor of claim 1 , wherein the embedded portion of the anode lead tape includes one or more recesses.

4. The solid electrolytic capacitor of claim 1 , wherein the embedded portion of the anode lead tape includes one or more hollow cavities.

5. The solid electrolytic capacitor of claim 1 , wherein the anode lead tape is generally rectangular or has a racetrack oval shape.

6. The solid electrolytic capacitor of claim 1 , wherein the second portion of the carrier lead wire is generally circular.

7. The solid electrolytic capacitor of claim 6 , wherein the diameter of the second portion of the carrier lead wire is less than the width of the anode lead tape.

8. The solid electrolytic capacitor of claim 1 , wherein the substantially planar surface of the first portion of the second anode lead is connected to the external portion of the anode lead tape by resistance welding.

9. The solid electrolytic capacitor of claim 1 , further comprising an anode termination, wherein the second portion of carrier lead wire is connected to the anode termination by laser welding.

10. The solid electrolytic capacitor of claim 1 , further comprising a cathode termination that is electrically connected to the cathode.

11. The solid electrolytic capacitor of claim 1 , wherein the anode body is formed from a powder comprising tantalum, niobium, aluminum, hafnium, titanium, an electrically conductive oxide thereof, or an electrically conductive nitride thereof.

12. A method for forming a solid electrolytic capacitor, the method comprising:

positioning an anode lead tape within a powder formed from a valve metal composition such that the anode lead tape includes an embedded portion located within a porous anode body and an external portion extending from a surface of the porous anode body in a longitudinal direction, wherein the anode lead tape has a width and a height, wherein the ratio of the width of the anode lead tape to the height of the anode lead tape is from about 1.5 to about 10;

compacting the powder around the embedded portion of the anode lead tape;

sintering the compacted powder to form a sintered, porous anode body;

positioning a carrier lead wire external to the sintered, porous anode body, wherein the carrier lead wire comprises a first portion and a second portion, wherein the first portion has a width that is greater than a width of the second portion, wherein the first portion includes a substantially planar surface, and wherein the width of the first portion of the carrier lead wire is smaller than the width of the anode lead tape;

connecting the substantially planar surface of the first portion of the carrier lead wire to the external portion of the anode lead tape; and

connecting the second portion of the carrier lead wire to an anode termination to form an electrical connection between the second portion of the carrier lead wire and the anode termination.

13. The method of claim 12 , further comprising trimming excess anode lead material from the carrier lead wire after welding the second portion of the carrier lead wire to the anode termination.

14. The method of claim 12 , wherein the sintered, porous anode body has a width, wherein the width of the anode lead tape is from about 25% to about 85% of the width of the sintered, porous anode body.

15. The method of claim 12 , further comprising forming one or more recesses or hollow cavities in the embedded portion of the anode lead tape.

16. The method of claim 12 , wherein the second portion of the carrier lead wire is circular, wherein the diameter of the second portion of the carrier lead wire is less than the width of the anode lead tape.

17. The method of claim 12 , wherein the first portion of the carrier lead wire is connected to the external portion of the anode lead tape by resistance welding.

18. The method of claim 12 , wherein the second portion of the second anode lead is connected to the anode termination by laser welding.

19. The method of claim 12 , further comprising:

anodically oxidizing the sintered, porous anode body to form a dielectric layer; and

applying a solid electrolyte to the anodically oxidized sintered, porous anode body to form a cathode.

20. The method of claim 19 , further comprising:

forming an electrical connection between the cathode and a cathode termination; and

encapsulating the capacitor with a molding material such that at least a part of the anode termination and a part of the cathode termination remain exposed.