# US 2013/0155582 A1 · Stack capacitor having high volumetric efficiency

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- Number: US 2013/0155582 A1
- Document ID: US20130155582A1
- Status: Published application
- Kind: A1
- Application number: 13/325,659
- Filed: 2011-12-14
- Published: 2013-06-20
- Earliest claimed: 2011-12-14
- Assignees: Kemet Electronics Corporation
- Inventors: Liancai Ning; Chris Stolarski; Qun Ya
- Web page: https://patentgrep.com/patent/US20130155582A1

## CPC

- H01G 9/02: Diaphragms; Separators
- H01G 9/0036: {Formation of the solid electrolyte layer}
- H01G 9/025: Solid electrolytes (H01G11/54 takes precedence)
- H01G 9/0425: {specially adapted for cathode}
- H01G 9/15: Solid electrolytic capacitors (H01G11/00 takes precedence)
- H01G 9/012: specially adapted for solid capacitors
- H01G 9/028: Organic semiconducting electrolytes, e.g. TCNQ
- H01G 9/032: Inorganic semiconducting electrolytes, e.g. MnO2
- H01G 9/26: Structural combinations of electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices with each other
- Y10T 29/43: Electric condenser making
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An improved capacitor and method of making an improved capacitor is set forth. The capacitor has planer anodes with each anode comprising a fusion end and a separated end and the anodes are in parallel arrangement with each anode in direct electrical contact with all adjacent anodes at the fusion end. A dielectric is on the said separated end of each anode wherein the dielectric covers at least an active area of the capacitor. Spacers separate adjacent dielectrics and the interstitial space between the adjacent dielectrics and spacers has a conductive material in therein.

## Claims

### Claim 1

A capacitor comprising:
planer anodes with each anode of said anodes comprising a fusion end and a separated end and said anodes are in parallel arrangement with each anode in direct electrical contact with all adjacent anodes at said fusion end;
a dielectric on said separated end of each said anode wherein said dielectric covers at least an active area of said capacitor;
spacers separating adjacent dielectrics;
interstitial spaces between said adjacent dielectrics and said spacers; and
a conductive material in said interstitial spaces.

### Claim 2 (depends on 1)

The capacitor of claim 1 wherein said interstitial spaces do not contain a conductive carbon layer or a conductive metal layer.

### Claim 3 (depends on 1)

The capacitor of claim 1 wherein said conductive material is selected from intrinsically conductive polymers, charge transfer conducting compounds or conductive oxides.

### Claim 4 (depends on 3)

The capacitor of claim 3 wherein said conductive material comprises a polythiophene, polypyrrole, or polyaniline or any of their derivatives.

### Claim 5 (depends on 4)

The capacitor of claim 4 wherein said conductive material comprises poly 3,4-ethylene dioxythiophene.

### Claim 6 (depends on 3)

The capacitor of claim 3 wherein said conductive material comprises manganese dioxide.

### Claim 7 (depends on 3)

The capacitor of claim 3 wherein said conductive material is in direct contact with said adjacent dielectrics.

### Claim 8 (depends on 1)

The capacitor of claim 1 comprising at least 2 planer anodes to no more than 40 planer anodes.

### Claim 9 (depends on 8)

The capacitor of claim 8 comprising at least 8 planer anodes to no more than 20 planer anodes.

### Claim 10 (depends on 1)

The capacitor of claim 1 wherein said spacer comprises fibers.

### Claim 11 (depends on 10)

The capacitor of claim 10 wherein said fibers have an average cross-sectional size of at least 1 to no more than 100 μm in the diameter direction.

### Claim 12 (depends on 10)

The capacitor of claim 10 wherein said fibers have a length of at least 1 to no more than 150 μm.

### Claim 13 (depends on 10)

The capacitor of claim 10 wherein said fibers comprise a polymeric material.

### Claim 14 (depends on 1)

The capacitor of claim 1 wherein said spacer is a carbonized fiber.

### Claim 15 (depends on 14)

The capacitor of claim 14 wherein said carbonized fiber has an average cross-sectional size of at least 1 to no more than 100 μm in the diameter direction.

### Claim 16 (depends on 14)

The capacitor of claim 14 wherein said carbonized fiber has an average length of at least 1 to no more than 150 μm.

### Claim 17 (depends on 1)

The capacitor of claim 1 wherein said spacers span the separation between said adjacent dielectrics.

### Claim 18 (depends on 1)

The capacitor of claim 1 wherein said planer anodes comprise a valve metal or a conductive oxide of a valve metal.

### Claim 19 (depends on 18)

The capacitor of claim 18 wherein said planer anode comprises a material selected from the group consisting of Ta, Nb, Al, NbO, Ti, Zr and alloys thereof.

### Claim 20 (depends on 1)

The capacitor of claim 1 wherein said conductive material further encases said active region of said capacitor.

### Claim 21 (depends on 20)

The capacitor of claim 20 further comprising a conductive carbon layer encasing said conductive material.

### Claim 22 (depends on 21)

The capacitor of claim 21 further comprising a conductive metal layer encasing said conductive carbon layer.

### Claim 23 (depends on 1)

The capacitor of claim 1 further comprising a cathode external termination in electrical contact with said conductive material and an anode external termination in electrical contact with said anodes.

### Claim 24

A method of making a capacitor comprising:
providing planer anodes wherein each anode of said anodes comprises a fusing end and a separated end wherein each said anode comprises a dielectric covering at least a portion of said separated end;
applying a matrix to said dielectric of at least a portion of said anodes wherein said matrix comprises a binder and a spacer;
forming a layered stack of said anodes wherein at least one matrix is between adjacent dielectrics;
fusing said anodes at said fusing end;
partially removing said binder thereby forming interstitial spaces between said adjacent dielectrics with said adjacent dielectrics separated by said spacers;
inserting a conductive material in said interstitial spaces and over an exterior of said layered stack;
electrically attaching an anode lead to said fused anodes; and
electrically attaching a cathode lead to said conductive material.

### Claim 25 (depends on 24)

The method of forming a capacitor of claim 24 further comprising:
forming a conductive carbon layer on said conductive coating over said exterior of said layered stack prior to said electrically attaching said cathode lead.

### Claim 26 (depends on 25)

The method of forming a capacitor of claim 25 further comprising:
forming a metal layer on said conductive carbon layer prior to said electrically attaching said cathode lead.

### Claim 27 (depends on 24)

The method of forming a capacitor of claim 24 wherein said removing of said binder includes heating said binder.

### Claim 28 (depends on 24)

The method of forming a capacitor of claim 24 wherein said anode comprises a material selected from the group consisting of Ta, Nb, Al, NbO, Ti, Zr and alloys thereof.

### Claim 29 (depends on 24)

The method of forming a capacitor of claim 24 wherein said conductive material is selected from intrinsically conductive polymers, charge transfer conducting compounds or conductive oxides.

### Claim 30 (depends on 29)

The method of forming a capacitor of claim 29 wherein said conductive material comprises a polythiophene.

### Claim 31 (depends on 30)

The method of forming a capacitor of claim 30 wherein said conductive material comprises poly 3,4-ethylene dioxythiophene.

### Claim 32 (depends on 29)

The method of forming a capacitor of claim 29 wherein said conductive material comprises manganese dioxide.

### Claim 33 (depends on 29)

The method of forming a capacitor of claim 29 wherein said inserting said conductive polymer comprises introduction of an oxidizer and a monomer into said interstitial spaces.

### Claim 34 (depends on 33)

The method of forming a capacitor of claim 33 wherein said monomer is introduced into said interstitial space prior to introduction of said oxidizer.

### Claim 35 (depends on 29)

The method of forming a capacitor of claim 29 wherein said inserting said conductive polymer comprises introduction of a slurry comprising said polymer to said interstitial space.

### Claim 36 (depends on 24)

The method of forming a capacitor of claim 24 wherein said spacer comprises carbonized fibers.

### Claim 37 (depends on 36)

The method of forming a capacitor of claim 36 wherein said fibrous materials have an average cross-sectional size at least 1 to no more than 100 μm along the diameter direction.

### Claim 38 (depends on 36)

The method of forming a capacitor of claim 36 wherein said carbonized fibers have a length of at least 1 to no more than 150 μm.

### Claim 39 (depends on 24)

The method of forming a capacitor of claim 24 further comprising carbonizing a polymer to form said spacer.

### Claim 40 (depends on 39)

The method of forming a capacitor of claim 39 wherein said polymer comprises hydroxy or carboxylic groups.

### Claim 41 (depends on 39)

The method of forming a capacitor of claim 39 wherein said polymer comprises at least one material selected from cellulose and pentosan.

### Claim 42 (depends on 41)

The method of forming a capacitor of claim 41 wherein said polymer comprises 25-85 wt % cellulose.

### Claim 43 (depends on 41)

The method of forming a capacitor of claim 41 wherein said polymer comprises 15-75 wt % pentosan.

### Claim 44 (depends on 24)

The method of forming a capacitor of claim 24 wherein said binder comprises a material selected from the group consisting of fibrin, cellulose, glucose, protein and gelatin.

### Claim 45 (depends on 44)

The method of forming a capacitor of claim 44 wherein said binder is starch.

### Claim 46 (depends on 24)

The method of forming a capacitor of claim 24 wherein said inserting said conductive material comprises applying vacuum to said layered stack.

### Claim 47 (depends on 24)

The method of forming a capacitor of claim 24 wherein said fusing said anodes comprises welding.

### Claim 48 (depends on 24)

The method of forming a capacitor of claim 24 comprising at least 2 planer anodes to no more than 40 planer anodes.

### Claim 49 (depends on 48)

The method of forming a capacitor of claim 48 comprising at least 8 planer anodes to no more than 20 planer anodes.

### Claim 50 (depends on 24)

The method of forming a capacitor of claim 24 wherein said forming said stacked layer comprises alternating anodes comprising said matrix coating with anodes not comprising said matrix coating.