Solid electrolytic capacitor and method for manufacturing same

A method for manufacturing a solid electrolytic capacitor, the method comprising:

• (i) forming a dielectric layer on at least a part of a surface of an anode foil, the anode foil including a base material part and a porous part disposed on a surface of the base material part;
• (ii) compressing or partially removing, after defining an anode section, a cathode formation section, and a separation section located between the anode section and the cathode formation section in the anode foil on which the dielectric layer is formed, the porous part in the separation section;
• (iii) disposing a first insulating material on a surface of the separation section;
• (iv) covering at least a part of the dielectric layer in the cathode formation section with a solid electrolyte layer;
• (v) covering at least a part of the solid electrolyte layer with a cathode lead-out layer;
• and
• (vi) after step (v), impregnating the porous part in at least a part of a region of the separation section with a second insulating material, the region of the separation section being covered with the first insulating material.

A solid electrolytic capacitor comprising:

• a capacitor element including:
• an anode foil including a base material part and a porous part disposed on a surface of the base material part;
• a dielectric layer disposed on a surface of the anode foil;
• a solid electrolyte layer covering at least a part of the dielectric layer;
• and
• a cathode lead-out layer covering at least a part of the solid electrolyte layer, wherein:
• the anode foil includes an anode section on which the solid electrolyte layer is not disposed, a cathode formation section on which the solid electrolyte layer is disposed, and a separation section located between the anode section and the cathode formation section,
• a first insulating material is disposed on or included in at least a part of the separation section;
• and
• the capacitor element further includes a second insulating material in at least a part of a region of the separation section, the region of the separation section being located closer to the anode section than the first insulating material.

A solid electrolytic capacitor comprising:

• a capacitor element including:
• an anode foil including a base material part and a porous part disposed on a surface of the base material part;
• a dielectric layer disposed on a surface of the anode foil;
• a solid electrolyte layer covering at least a part of the dielectric layer;
• and
• a cathode lead-out layer covering at least a part of the solid electrolyte layer, wherein:
• the anode foil includes an anode section on which the solid electrolyte layer is not disposed, a cathode formation section on which the solid electrolyte layer is disposed, and a separation section located between the anode section and the cathode formation section,
• a first insulating material is disposed on or included in at least a part of the separation section;
• and
• the solid electrolyte layer covers at least a part of a region of the separation section, the region of the separation being located closer to the cathode formation section than the first insulating material.

A solid electrolytic capacitor comprising:

• a capacitor element including:
• an anode foil including a base material part and a porous part disposed on a surface of the base material part;
• a dielectric layer disposed on a surface of the anode foil;
• a solid electrolyte layer covering at least a part of the dielectric layer;
• and
• a cathode lead-out layer covering at least a part of the solid electrolyte layer, wherein:
• the anode foil includes an anode section on which the solid electrolyte layer is not disposed, a cathode formation section on which the solid electrolyte layer is disposed, and a separation section located between the anode section and the cathode formation section;
• a first insulating material is disposed on or included in at least a part of the separation section;
• a second groove is formed to be adjacent to the first insulating material at a side close to the cathode formation section in the separation section;
• and
• the solid electrolyte layer is disposed in at least a part of the second groove.

A solid electrolytic capacitor comprising:

• a capacitor element including:
• an anode foil including a base material part and a porous part disposed on a surface of the base material part;
• a dielectric layer disposed on a surface of the anode foil;
• a solid electrolyte layer covering at least a part of the dielectric layer;
• and
• a cathode lead-out layer covering at least a part of the solid electrolyte layer, wherein:
• the anode foil includes an anode section on which the solid electrolyte layer is not disposed, a cathode formation section on which the solid electrolyte layer is disposed, and a separation section located between the anode section and the cathode formation section;
• a first insulating material is disposed on or included in at least a part of the separation section;
• a third groove is formed in at least a part of the cathode formation section;
• and
• the solid electrolyte layer is disposed in at least a part of the third groove.

A solid electrolytic capacitor comprising:

• a capacitor element including:
• an anode foil including a base material part and a porous part disposed on a surface of the base material part;
• a dielectric layer disposed on a surface of the anode foil;
• a solid electrolyte layer covering at least a part of the dielectric layer;
• and
• a cathode lead-out layer covering at least a part of the solid electrolyte layer, wherein:
• the anode foil includes an anode section on which the solid electrolyte layer is not disposed, a cathode formation section on which the solid electrolyte layer is disposed, and a separation section located between the anode section and the cathode formation section;
• a first insulating material is disposed on or included in at least a part of the separation section;
• a second groove is formed to be adjacent to the first insulating material at a side close to the cathode formation section in the separation section;
• and
• a second insulating material is disposed in at least a part of the second groove.

A method for manufacturing a solid electrolytic capacitor, the method comprising:

• (i) forming a dielectric layer on at least a part of a surface of an anode foil, the anode foil including a base material part and porous part disposed on a surface of the base material part;
• (ii) conducting at least one of compression or removal of after defining an anode section, a cathode formation section, and a separation section between the anode section and the cathode formation section in the anode foil on which the dielectric layer is formed, at least a part of the porous part in the separation section;
• (iii) disposing a first insulating material in at least a part of the separation section or impregnating the at least a part of the separation section with the first insulating material;
• (iv) covering at least a part of the dielectric layer in the cathode formation section with a solid electrolyte layer;
• (v) covering at least a part of the solid electrolyte layer with a cathode lead-out layer;
• and
• (vi) after step (v), disposing a second insulating material in at least a part of a region of the separation section or impregnating the at least a part of the region of the separation section with the second insulating material, the region of the separation section being located closer to the anode section than the first insulating material.