Solid electrolytic capacitor with improved leakage current

1. A capacitor assembly comprising a capacitor element, the capacitor element comprising:

a sintered porous anode body;

a dielectric that overlies the anode body;

a pre-coat layer that overlies the dielectric that is formed from an organometallic compound;

a solid electrolyte that overlies the pre-coat layer, wherein the solid electrolyte contains an inner layer and an outer layer, wherein the inner layer is formed from an in situ-polymerized conductive polymer and the outer layer is formed from pre-polymerized conductive polymer particles, and wherein the inner layer is formed with an oxidative catalyst that includes transition metal cations.

2. The capacitor assembly of claim 1 , wherein the anode body includes tantalum and the dielectric includes tantalum pentoxide.

3. The capacitor assembly of claim 1 , wherein the organometallic compound has the following general formula:

wherein,

M is an organometallic atom;

R 1 , R 2 , and R 3 are independently an alkyl or a hydroxyalkyl, wherein at least one of R 1 , R 2 , and R 3 is a hydroxyalkyl;

n is an integer from 0 to 8;

X is an organic or inorganic functional group.

4. The capacitor assembly of claim 3 , wherein M is silicon.

5. The capacitor assembly of claim 4 , wherein the hydroxyalkyl is OCH 3 .

6. The capacitor assembly of claim 3 , wherein R 1 , R 2 , and R 3 are a hydroxyalkyl.

7. The capacitor assembly of claim 1 , wherein the organometallic compound is 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-aminopropylmethyldimethoxysilane, 3-aminopropylmethyldiethoxysilane, 3-(2-aminoethyl)aminopropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane, 3-mercaptopropylmethyldimethoxysilane, 3-mercaptopropylmethyldiethoxysilane, glycidoxymethyltrimethoxysilane, glycidoxymethyltriethoxysilane, glycidoxymethyl-tripropoxysilane, glycidoxymethyltributoxysilane, β-glycidoxyethyltrimethoxysilane, β-glycidoxyethyltriethoxysilane, β-glycidoxyethyl-tripropoxysilane, β-glycidoxyethyl-tributoxysilane, β-glycidoxyethyltrimethoxysilane, α-glycidoxyethyltriethoxysilane, α-glycidoxyethyltripropoxysilane, α-glycidoxyethyltributoxysilane, γ-glycidoxypropyl-trimethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-glycidoxypropyl-tripropoxysilane, γ-glycidoxypropyltributoxysilane, β-glycidoxypropyltrimethoxysilane, β-glycidoxypropyl-triethoxysilane, β-glycidoxypropyltripropoxysilane, α-glycidoxypropyltributoxysilane, α-glycidoxypropyltrimethoxysilane, α-glycidoxypropyltriethoxysilane, α-glycidoxypropyl-tripropoxysilane, α-glycidoxypropyltributoxysilane, γ-glycidoxybutyltrimethoxysilane, δ-glycidoxybutyltriethoxysilane, δ-glycidoxybutyltripropoxysilane, δ-glycidoxybutyl-tributoxysilane, δ-glycidoxybutyltrimethoxysilane, γ-glycidoxybutyltriethoxysilane, γ-glycidoxybutyltripropoxysilane, γ-propoxybutyltributoxysilane, δ-glycidoxybutyl-trimethoxysilane, δ-glycidoxybutyltriethoxysilane, δ-glycidoxybutyltripropoxysilane, α-glycidoxybutyltrimethoxysilane, α-glycidoxybutyltriethoxysilane, α-glycidoxybutyl-tripropoxysilane, α-glycidoxybutyltributoxysilane, or a combination thereof.

8. The capacitor assembly of claim 1 , wherein the inner layer is formed by 3,4-ethylenedioxthiophene or a derivative thereof, with an oxidative catalyst, wherein the catalyst includes an iron (III) salt of an aromatic sulfonic acid.

9. The capacitor assembly of claim 1 , wherein the solid electrolyte contains from 2 to 30 inner layers that are formed from an in situ-polymerized conductive polymer.

10. The capacitor assembly of claim 1 , wherein the outer layer is formed from a dispersion of particles that contain a polymeric counterion and an extrinsically conductive polymer, wherein the extrinsically conductive polymer is poly(3,4-ethylenedioxythiophene) or a derivative thereof.

11. The capacitor assembly of claim 1 , wherein the outer layer is formed from an intrinsically conductive polymer having repeating units of the following formula:

wherein,

R is (CH 2 ) a —O—(CH 2 ) b ;

a is from 0 to 10;

b is from 1 to 18;

Z is an anion;

X is a cation.

12. The capacitor assembly of claim 1 , wherein at least a portion of the pre-polymerized conductive polymer particles in the solid electrolyte have an average size of from about 1 to about 80 nanometers.

13. The capacitor assembly of claim 1 , wherein the outer layer is generally free of in situ-polymerized conductive polymers.

14. The capacitor assembly of claim 1 , wherein the solid electrolyte contains from 2 to 30 outer layers that are formed from pre-polymerized conductive polymer particles.

15. The capacitor assembly of claim 1 , further comprising an external polymer coating that overlies the solid electrolyte and contains pre-polymerized conductive polymer particles and a cross-linking agent.

16. The capacitor assembly of claim 15 , wherein at least a portion of the conductive polymer particles in the external polymer coating have an average size of from about 80 to about 500 nanometers.

17. The capacitor assembly of claim 1 , further comprising an anode termination that is in electrical connection with the anode body;

a cathode termination that is in electrical connection with the solid electrolyte; and

a housing that encloses the capacitor element and leaves exposed at least a portion of the anode termination and the cathode termination.

18. The capacitor assembly of claim 17 , wherein the housing is formed from a resinous material that encapsulates the capacitor element.

19. The capacitor assembly of claim 17 , wherein the housing defines an interior cavity within which the capacitor element is positioned, wherein the interior cavity has a gaseous atmosphere that includes an inert gas.

20. The capacitor assembly of claim 1 , wherein after being subjected to an applied voltage for 90 seconds, the assembly exhibits a leakage current of about 50 microamps or less.

21. The capacitor assembly of claim 1 , wherein after being subjected to an applied voltage for 180 seconds, the assembly exhibits a leakage current that is greater than 50% of the leakage current exhibited after being subjected to the applied voltage for 90 seconds.

22. The capacitor assembly of claim 21 , wherein the assembly exhibits a leakage current of about 20 microamps or less after being subjected to the applied voltage for 180 seconds.

23. A method for forming a capacitor assembly, the method comprising:

anodically oxidizing a sintered porous anode body to form an anode;

applying a solution to the anode that includes an organometallic compound having the following general formula:

wherein,

M is an organometallic atom;

r 1 , r 2 , and r 3 are independently an alkyl or a hydroxyalkyl, wherein at least one of R 1 , R 2 , and R 3 is a hydroxyalkyl;

n is an integer from 0 to 8;

X is an organic or inorganic functional group;

polymerizing a conductive polymer precursor monomer in the presence of an oxidative catalyst that includes transition metal cations to form an inner solid electrolyte layer that overlies the pre-coat layer; and

applying a dispersion of conductive polymer particles to form an outer solid electrolyte layer that overlies the inner solid electrolyte layer.

24. The method of claim 23 , wherein the solution includes an organic solvent.

25. The method of claim 24 , further comprising drying the solution after application to the anode.

26. The method of claim 23 , wherein the precursor monomer and oxidative catalyst are sequentially applied.

27. The method of claim 23 , wherein at least a portion of the conductive polymer particles have an average size of from about 1 to about 80 nanometers.