Solid electrolytic capacitor element, solid electrolytic capacitor, and method for manufacturing solid electrolytic capacitor element

Abstract

A solid electrolytic capacitor element 1 comprises: an anode 10 that is formed from a valve-action metal substrate 11 and has a distal end surface 10a and a proximal end surface 10b; a dielectric layer 20 that is provided on at least one of main surfaces 10c, 10d of the anode 10 except for at least the proximal end surface 10b; a mask layer 30 that is formed from an insulating material and is provided on the dielectric layer 20 along the proximal end surface 10b; and a cathode 40 that is provided on the dielectric layer 20 further on the distal end surface 10a side than the mask layer 30. The cathode 40 has a solid electrolyte layer 50 provided on the dielectric layer 20, and a conductive layer 60 provided on the solid electrolyte layer 50. The solid electrolyte layer 50 has a protrusion 51 along the mask layer 30, and the maximum thicknesses t1, t2 of the solid electrolyte layer 50 at the protrusion 51 are greater than the thickness of the solid electrolyte layer 50 at a remaining portion 52 excluding the protrusion 51.

Description

[Technical field]

[0001] The present invention relates to a solid electrolytic capacitor element, a solid electrolytic capacitor, and a method for manufacturing a solid electrolytic capacitor element. [Background technology]

[0002] Patent Document 1 discloses a solid electrolytic capacitor element that has a masking portion (mask layer) for insulating the anode portion from the cathode portion to prevent the solid electrolyte from creeping up, and in which the thickness of the solid electrolyte layer at the periphery of the valve action metal porous substrate is greater than the thickness of the solid electrolyte layer at the center of the valve action metal porous substrate. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] WO 01 / 75917 Summary of the Invention [Problem to be solved by the invention]

[0004] In the solid electrolytic capacitor element, the solid electrolyte layer is easily thinned and stressed near the mask layer, so that the conductive layer on the solid electrolyte layer is easily in contact with the dielectric layer in this vicinity, and leakage current is easily generated due to tunnel current. As a result, there is a risk of deterioration in the withstand voltage and reflow resistance. Note that reflow resistance refers to the resistance of the finished solid electrolytic capacitor to stress during reflow.

[0005] In response to this, as described in Patent Document 1, it is expected that increasing the thickness of the solid electrolyte layer in the peripheral portion of the substrate will lead to a reduction in leakage current.

[0006] However, in the solid electrolytic capacitor element described in Patent Document 1, if the thickness of the solid electrolyte layer around the periphery of the substrate is made thicker overall in order to further suppress the occurrence of leakage current, the thickness of the solid electrolytic capacitor element also becomes thicker than necessary in the periphery of the substrate other than near the mask layer, and when the solid electrolytic capacitor elements are stacked to assemble a solid electrolytic capacitor, the volumetric efficiency of the assembled solid electrolytic capacitor deteriorates.

[0007] The present invention has been made to solve the above problems, and aims to provide a solid electrolytic capacitor element and a method for manufacturing a solid electrolytic capacitor element that can realize a thin solid electrolytic capacitor with excellent voltage resistance and reflow resistance. Another aim of the present invention is to provide a thin solid electrolytic capacitor with excellent voltage resistance and reflow resistance. [Means for solving the problem]

[0008] The solid electrolytic capacitor element of the present invention comprises: an anode made of a valve action metal base and having a tip surface and a base surface; a dielectric layer provided on at least one main surface of the anode excluding at least the base surface; a mask layer made of an insulating material and provided on the dielectric layer along the base surface; and a cathode provided on the dielectric layer on the tip surface side of the mask layer, the cathode having a solid electrolyte layer provided on the dielectric layer and a conductive layer provided on the solid electrolyte layer, the solid electrolyte layer having a convex portion along the mask layer, and a maximum thickness of the solid electrolyte layer at the convex portion being greater than a thickness of the solid electrolyte layer in a remainder excluding the convex portion.

[0009] The solid electrolytic capacitor of the present invention includes a laminate in which a plurality of solid electrolytic capacitor elements of the present invention are laminated.

[0010] The method for manufacturing a solid electrolytic capacitor element of the present invention includes a first step of immersing the anode having the mask layer formed on the dielectric layer in a treatment liquid containing a solid electrolyte from the front end surface side until it contacts the mask layer, and a second step of pulling the anode out of the treatment liquid and drying the treatment liquid, wherein in the second step, the anode is dried in a state in which it is inverted upside down from when it was immersed. Effect of the Invention

[0011] According to the present invention, it is possible to provide a solid electrolytic capacitor element capable of realizing a thin solid electrolytic capacitor having excellent pressure resistance and reflow resistance, and a method for manufacturing a solid electrolytic capacitor element. Furthermore, according to the present invention, it is possible to provide a thin solid electrolytic capacitor having excellent pressure resistance and reflow resistance. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a plan view showing a schematic diagram of an example of a solid electrolytic capacitor element according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view taken along line XX of the solid electrolytic capacitor element shown in FIG. [Diagram 3] FIG. 3 is a cross-sectional view taken along line YY of the solid electrolytic capacitor element shown in FIG. [Figure 4] FIG. 4 is an enlarged cross-sectional view of the base end portion of the solid electrolytic capacitor element shown in FIG. [Diagram 5] FIG. 5 is an enlarged cross-sectional view of a mask layer portion of the solid electrolytic capacitor element shown in FIG. [Figure 6] FIG. 6 is a plan view illustrating an example of a solid electrolytic capacitor element according to another embodiment of the present invention. [Figure 7] FIG. 7 is a cross-sectional view taken along the line XX of the solid electrolytic capacitor element shown in FIG. [Figure 8] FIG. 8 is a cross-sectional view taken along line YY of the solid electrolytic capacitor element shown in FIG. [Figure 9]FIG. 9 is a cross-sectional view that illustrates a schematic example of a solid electrolytic capacitor element according to still another embodiment of the present invention. [Figure 10] FIG. 10 is a schematic diagram showing an example of a step of immersing the anode on which the mask layer has been formed, in a treatment liquid containing a solid electrolyte. [Figure 11] FIG. 11 is a schematic diagram showing an example of a step of pulling the anode out of the treatment liquid and drying the treatment liquid. [Figure 12] FIG. 12 is a schematic view showing another example of the step of pulling the anode out of the treatment liquid and drying the treatment liquid. [Figure 13] FIG. 13 is a plan view that illustrates an example of a solid electrolytic capacitor element after the solid electrolyte layer is formed through the drying step shown in FIG. [Figure 14] FIG. 14 is a plan view that illustrates an example of a solid electrolytic capacitor element after the solid electrolyte layer is formed through the drying step shown in FIG. [Figure 15] FIG. 15 is a schematic diagram showing an example of a step of preparing a valve metal substrate having a mask layer formed thereon. [Figure 16] FIG. 16 is a schematic diagram showing an example of a process for forming a solid electrolyte layer. [Figure 17] FIG. 17 is a perspective view that illustrates an example of a solid electrolytic capacitor according to an embodiment of the present invention. [Figure 18] FIG. 18 is a cross-sectional view taken along line ZZ of the solid electrolytic capacitor shown in FIG. [Figure 19] FIG. 19 is a cross-sectional view illustrating an example of a solid electrolytic capacitor according to another embodiment of the present invention. [Figure 20] FIG. 20 is a cross-sectional view illustrating a schematic example of a solid electrolytic capacitor according to still another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The solid electrolytic capacitor element, the solid electrolytic capacitor, and the method for producing the solid electrolytic capacitor element of the present invention will be described below. However, the present invention is not limited to the following configurations, and can be modified as appropriate within the scope of the present invention. Note that the present invention also includes a combination of two or more of the individual desirable configurations described below.

[0014] In addition, the embodiments described below are merely examples, and it goes without saying that partial replacement or combination of the configurations described in different embodiments is possible. Repetition of descriptions of matters common to multiple embodiments will be omitted, and only differences will be described.

[0015] [Solid electrolytic capacitor element] Fig. 1 is a plan view showing a schematic diagram of an example of a solid electrolytic capacitor element according to an embodiment of the present invention. Fig. 2 is a cross-sectional view taken along line XX of the solid electrolytic capacitor element shown in Fig. 1. Fig. 3 is a cross-sectional view taken along line YY of the solid electrolytic capacitor element shown in Fig. 1. Fig. 4 is an enlarged cross-sectional view of a base end portion of the solid electrolytic capacitor element shown in Fig. 2. In Fig. 1, the conductive layer 60 of the cathode 40 is shown by a dashed line, and the conductive layer 60 is shown in a see-through state.

[0016] The solid electrolytic capacitor element 1 shown in Figures 1, 2, 3, and 4 includes an anode 10 made of a valve metal substrate 11 and having a tip end surface 10a and a base end surface 10b, a dielectric layer 20 provided on the surface of the anode 10 except for the base end surface 10b, a mask layer 30 made of an insulating material and provided on the dielectric layer 20 along the base end surface 10b, and a cathode 40 provided on the dielectric layer 20 on the tip end surface 10a side of the mask layer 30, and the cathode 40 has a solid electrolyte layer 50 provided on the dielectric layer 20 and a conductive layer 60 provided on the solid electrolyte layer 50.

[0017] Then, on the side of one main surface 10c of the anode 10, the solid electrolyte layer 50 has a convex portion 51a along the mask layer 30, and the maximum thickness t1 (see FIG. 4) of the solid electrolyte layer 50 at the convex portion 51a is larger than the thickness of the solid electrolyte layer 50 at the remaining portion 52a excluding the convex portion 51a. Similarly, on the other main surface 10d side of the anode 10, the solid electrolyte layer 50 has a convex portion 51b along the mask layer 30, and the maximum thickness t2 (see FIG. 4) of the solid electrolyte layer 50 at the convex portion 51b is greater than the thickness of the solid electrolyte layer 50 in the remaining portion 52b excluding the convex portion 51b. This makes it possible to selectively increase the thickness of the solid electrolyte layer 50 near the mask layer 30 while preventing the thickness of the solid electrolyte layer 50 from being increased more than necessary in other regions. Therefore, while effectively suppressing the occurrence of leakage current near the mask layer 30, it is possible to reduce the overall thickness of the solid electrolytic capacitor element 1 and improve the volumetric efficiency of the solid electrolytic capacitor including the solid electrolytic capacitor element 1. As a result, it is possible to simultaneously achieve an improvement in the withstand voltage and reflow resistance of the solid electrolytic capacitor while reducing its thickness.

[0018] In this specification, the term "protruding portion" includes the protruding portion on the surface and the base portion overlapping the protruding portion. Moreover, the "thickness of the solid electrolyte layer in the remainder" refers to the maximum thickness of the remainder of the solid electrolyte layer.

[0019] In addition, the region from the thickest part 53a of the protrusion 51a to the base end 54 of the solid electrolyte layer 50 located on the base end surface 10b side of the anode 10 is not covered with the conductive layer 60, and the region from the thickest part 53b of the protrusion 51b to the base end 54 of the solid electrolyte layer 50 located on the base end surface 10b side of the anode 10 is not covered with the conductive layer 60. That is, since the conductive layer 60 is not further provided on the thickest parts 53a and 53b of the protrusions 51a and 51b, the thickness of the entire solid electrolytic capacitor element 1 can be more effectively suppressed. In addition, the conductive layer 60 can be prevented from coming into contact with the dielectric layer 20 beyond the mask layer 30, and leakage current can be prevented. The thickest parts 53a and 53b are the parts where the thicknesses of the protrusions 51a and 51b are the thickest, respectively.

[0020] Furthermore, the thickness of the solid electrolytic capacitor element 1 in the remaining portions 52a and 52b does not exceed the thickness Tmax of the solid electrolytic capacitor element 1 in the thickest portions 53a and 53b. Therefore, the overall thickness of the solid electrolytic capacitor element 1 can be more effectively reduced.

[0021] Moreover, the remaining portions 52a and 52b are each flat. That is, the remaining portions 52a and 52b are thinner than the protruding portions 51a and 51b, respectively. Therefore, the conductive layer 60 can be selectively provided on the remaining portions 52a and 52b, which are relatively thinner than the protruding portions 51a and 51b, respectively, and therefore the thickness of the entire solid electrolytic capacitor element 1 can be further reduced. Also, a wide range of space can be secured on the flat remaining portions 52a and 52b to place the conductive adhesive.

[0022] Each component of solid electrolytic capacitor element 1 will be described in detail below. In this specification, when describing the configurations present on each of the main surfaces 10c and 10d of the anode 10, when they are to be described separately, the same reference numbers will be appended with "a" or "b" to distinguish them, and when they are to be described without distinction, the "a" and "b" will be omitted and only the same reference numbers will be appended.

[0023] The anode 10 is a thin film (foil) made of a valve metal substrate 11 and has a quadrangular shape in plan view, preferably a rectangular shape (strip shape) having a pair of long sides and a pair of short sides in plan view. The tip end face 10a and the base end face 10b are end faces located on a pair of sides (preferably a pair of short sides) of the anode 10, and the base end face 10b is an exposed end face that is not covered with the dielectric layer 20 and is exposed at one end face of the solid electrolytic capacitor and connected to an external electrode described later. The anode 10 has the tip end face 10a, the base end face 10b, main faces 10c and 10d, and side faces 10e and 10f.

[0024] In this specification, the term "planar view" means a view from the normal direction of the main surface of the anode (valve metal substrate).

[0025] FIG. 5 is an enlarged cross-sectional view of a mask layer portion of the solid electrolytic capacitor element shown in FIG.

[0026] As shown in Fig. 5, each main surface of the valve metal substrate 11 (anode 10) has a plurality of recesses. Therefore, each main surface of the valve metal substrate 11 is porous. This increases the surface area of ​​the valve metal substrate 11. Note that the present invention is not limited to the case where both main surfaces of the valve metal substrate 11 are porous, and only one of the main surfaces of the valve metal substrate 11 may be porous.

[0027] The valve metal substrate 11 is made of a valve metal, such as an elemental metal such as aluminum, tantalum, niobium, titanium, zirconium, or an alloy containing these metals. An oxide film can be formed on the surface of the valve metal.

[0028] The valve metal substrate 11 need only be composed of a core and a porous portion provided on at least one of the main surfaces of the core, and may be, for example, a metal foil having an etched surface or a metal foil having a porous sintered powder formed on the surface.

[0029] Here, the dielectric layer 20 is provided on the surface of the anode 10 except for the base end surface 10b. That is, the dielectric layer 20 is provided on the tip surface 10a, the main surfaces 10c and 10d, and the side surfaces 10e and 10f of the anode 10, but is not provided on the base end surface 10b of the anode 10. However, it is sufficient that the dielectric layer 20 is provided on at least one of the main surfaces 10c and 10d of the anode 10, excluding at least the base end surface 10b.

[0030] The dielectric layer 20 is preferably made of an oxide film provided on the surface of the valve metal base 11. For example, the dielectric layer 20 is made of an aluminum oxide. The aluminum oxide is formed by anodizing the surface of the valve metal base 11, as described later.

[0031] The mask layer 30 is a linear (strand-like) insulating member provided on the dielectric layer 20 along the base end surface 10b of the anode 10, preferably along the short side of the anode 10, and separates the anode 10 from the cathode 40 to ensure insulation between them. The mask layer 30 divides the anode 10 into an area on the base end surface 10b side and an area on the tip end surface 10a side. Here, the mask layer 30 is disposed at a predetermined distance from the base end surface 10b, but may be disposed up to the edge of the base end surface 10b. The mask layer 30 is provided on the main surfaces 10c and 10d and the side surfaces 10e and 10f of the anode 10 via the dielectric layer 20, but it is sufficient that the mask layer 30 is provided on at least one of the main surfaces 10c and 10d of the anode 10 (however, the main surface on which the dielectric layer 20 is provided).

[0032] 5, the mask layer 30 is preferably provided so as to fill a plurality of pores (recesses) in the valve metal base 11. However, it is sufficient that part of the outer surface of the dielectric layer 20 is covered with the mask layer 30, and there may be pores (recesses) in the valve metal base 11 that are not filled with the mask layer 30.

[0033] The mask layer 30 is made of an insulating material. The mask layer 30 is formed by applying a mask material such as a composition containing an insulating resin. Examples of the insulating resin include polyphenylsulfone (PPS), polyethersulfone (PES), cyanate ester resin, fluororesin (tetrafluoroethylene, tetrafluoroethylene-perfluoroalkylvinylether copolymer, etc.), a composition of soluble polyimidesiloxane and epoxy resin, polyimide resin, polyamideimide resin, and derivatives or precursors thereof.

[0034] The mask material can be applied by, for example, screen printing, roller transfer, dispenser, inkjet printing, or the like.

[0035] The cathode 40 has a solid electrolyte layer 50 provided on the dielectric layer 20 and a conductive layer 60 provided on the solid electrolyte layer 50. The cathode 40 is provided on the dielectric layer 20 on the front end surface 10a side of the mask layer 30. That is, the cathode 40 is provided on the dielectric layer 20 in a region on the front end surface 10a side of the anode 10 partitioned by the mask layer 30.

[0036] The solid electrolyte layer 50 is provided on the dielectric layer 20. As shown in Fig. 5, the solid electrolyte layer 50 is preferably provided so as to fill a plurality of pores (recesses) of the valve metal base 11. However, it is sufficient that part of the outer surface of the dielectric layer 20 is covered with the solid electrolyte layer 50, and there may be pores (recesses) of the valve metal base 11 that are not filled with the solid electrolyte layer 50.

[0037] The solid electrolyte layer 50 is provided on the dielectric layer 20 on the front end surface 10a side of the mask layer 30. That is, the solid electrolyte layer 50 is provided on the dielectric layer 20 in a region on the front end surface 10a side of the anode 10 partitioned by the mask layer 30.

[0038] A base end 54 of the solid electrolyte layer 50 is located on the outer main surface of the mask layer 30 (the main surface opposite to the anode 10). The solid electrolyte layer 50 may be provided so as to cover a part of the outer main surface of the mask layer 30 as shown in Fig. 4, or may be provided so as to cover the entire outer main surface of the mask layer 30. The solid electrolyte layer 50 may also be disposed next to and in contact with the mask layer 30 so as not to cover the entire outer main surface of the mask layer 30.

[0039] The solid electrolyte layer 50 has, on one main surface 10c side of the anode 10, a convex portion 51a along the mask layer 30 and a remainder 52a excluding the convex portion 51a, and has, on the other main surface 10d side of the anode 10, a convex portion 51b along the mask layer 30 and a remainder 52b excluding the convex portion 51b.

[0040] The protrusions 51 are thick portions where the solid electrolyte layer 50 is partially thickened, and are formed linearly (in a band shape) parallel to the mask layer 30. That is, the protrusions 51 are linear ridges. Here, as shown in FIG. 4, the protrusion 51 has an arc-shaped surface when viewed in cross section in a direction perpendicular to the mask layer 30, but may also have a trapezoidal or triangular surface.

[0041] In contrast, remaining portion 52 is a flat portion, and has a substantially constant thickness within the plane. Therefore, in solid electrolytic capacitor element 1, the thickness of solid electrolyte layer 50 in remaining portion 52 is the thickness of the flat portion.

[0042] 2, when viewed in cross section in a direction perpendicular to mask layer 30, solid electrolyte layer 50 has a shape that is approximately line symmetric with respect to anode 10. That is, protruding portions 51a and 51b have approximately the same shape, remaining portions 52a and 52b have approximately the same shape, and thickest portions 53a and 53b are located at approximately the same position on anode 10.

[0043] On the main surface 10c side of the anode 10, the maximum thickness t1 of the solid electrolyte layer 50 at the protrusion 51a is greater than the thickness of the solid electrolyte layer 50 at the remainder 52a, and on the main surface 10d side of the anode 10, the maximum thickness t2 of the solid electrolyte layer 50 at the protrusion 51b is greater than the thickness of the solid electrolyte layer 50 at the remainder 52b. That is, the solid electrolyte layer 50 is thickest at the protrusion 51a along the mask layer 30 on the main surface 10c side of the anode 10, and is thickest at the protrusion 51b along the mask layer 30 on the main surface 10d side of the anode 10.

[0044] More specifically, the difference between the maximum thickness t1 of solid electrolyte layer 50 at protrusion 51a and the thickness of solid electrolyte layer 50 at remainder 52a (e.g., the center of remainder 52a) is, for example, preferably 2 μm or more and 50 μm or less, more preferably 5 μm or more and 40 μm or less, and even more preferably 10 μm or more and 30 μm or less. The same applies to the difference between the maximum thickness t2 of the solid electrolyte layer 50 at the protrusion 51b and the thickness of the solid electrolyte layer 50 at the remainder 52b (for example, the center of the remainder 52b). The "thickness of the solid electrolyte layer" refers to the thickness in the normal direction of one of the main surfaces of the anode.

[0045] Materials constituting the solid electrolyte layer 50 include conductive polymers such as polypyrroles, polythiophenes, and polyanilines. Among these, polythiophenes are preferred, and poly(3,4-ethylenedioxythiophene), also known as PEDOT, is particularly preferred. The conductive polymers may contain dopants such as polystyrene sulfonate (PSS).

[0046] The solid electrolyte layer 50 is formed, for example, by a method of forming a polymerized film of a conductive polymer such as poly(3,4-ethylenedioxythiophene) on the surface of the dielectric layer 20 using a liquid containing a polymerizable monomer such as 3,4-ethylenedioxythiophene, or by a method of applying a dispersion liquid of a conductive polymer such as poly(3,4-ethylenedioxythiophene) to the surface of the dielectric layer 20 and drying it.

[0047] It is preferable to form an outer layer that covers the entire dielectric layer 20 after forming an inner layer that fills the pores (recesses) of the valve metal base 11. The inner layer can be formed by, for example, a dipping method, sponge transfer, screen printing, a dispenser, inkjet printing, etc. Similarly, the outer layer can be formed by, for example, a dipping method, sponge transfer, screen printing, a dispenser, inkjet printing, etc.

[0048] The conductive layer 60 is provided on the solid electrolyte layer 50. The conductive layer 60 is disposed up to just before the thickest portion 53 of the protrusion 51, and does not have to cover the entire protrusion 51 as shown in Fig. 4. The conductive layer 60 has a substantially constant thickness.

[0049] The conductive layer 60 includes, for example, a carbon layer or a cathode conductor layer. The conductive layer 60 may also be a composite layer in which a cathode conductor layer is provided on the outer surface of a carbon layer, or a mixed layer including carbon and a cathode conductor layer material.

[0050] The carbon layer is formed, for example, by a method in which a carbon paste containing carbon particles and resin is applied to the surface of the solid electrolyte layer 50 and then dried.

[0051] The carbon paste can be applied by, for example, a dipping method, sponge transfer, screen printing, spray application, a dispenser, inkjet printing, or the like.

[0052] The cathode conductor layer is formed, for example, by a method of applying a conductive paste containing metal particles such as gold, silver, copper, platinum, etc. and a resin to the surface of the solid electrolyte layer or the carbon layer and drying it. The cathode conductor layer is preferably a silver layer.

[0053] The conductive paste can be applied by, for example, a dipping method, sponge transfer, screen printing, spray application, a dispenser, inkjet printing, or the like.

[0054] The thickness of the solid electrolytic capacitor element 1 in the remaining portions 52a and 52b does not exceed the thickness Tmax of the solid electrolytic capacitor element 1 in the thickest portions 53a and 53b. That is, the thickness of the solid electrolytic capacitor element 1 in the remaining portions 52a and 52b is smaller than or approximately the same as the thickness Tmax of the solid electrolytic capacitor element 1 in the thickest portions 53a and 53b. In addition, when the convex portions 51a and 51b are present on both main surfaces of the anode 10, the thickness Tmax of the solid electrolytic capacitor element 1 at the thickest portions 53a and 53b may be the distance between two planes parallel to the anode 10 and passing through the vertices of the thickest portions 53a and 53b, respectively.

[0055] Fig. 6 is a plan view showing a schematic example of a solid electrolytic capacitor element according to another embodiment of the present invention. Fig. 7 is a cross-sectional view taken along line XX of the solid electrolytic capacitor element shown in Fig. 6. Fig. 8 is a cross-sectional view taken along line YY of the solid electrolytic capacitor element shown in Fig. 6. In Fig. 6, the conductive layer 60 of the cathode 40 is shown by a dashed line, and the conductive layer 60 is shown in a see-through state.

[0056] In the solid electrolytic capacitor element 2 shown in Figures 6, 7, and 8, the solid electrolyte layer 50 has, on the one main surface 10c side of the anode 10, an outer peripheral portion 55a including a protrusion 51a, and a central portion 56a surrounded by the outer peripheral portion 55a, and the thickness of the solid electrolyte layer 50 at the outer peripheral portion 55a is greater than the thickness of the solid electrolyte layer 50 at the central portion 56a. Similarly, the solid electrolyte layer 50 has, on the other main surface 10d side of the anode 10, an outer peripheral portion 55b including a protrusion 51b, and a central portion 56b surrounded by the outer peripheral portion 55b, and the thickness of the solid electrolyte layer 50 at the outer peripheral portion 55b is greater than the thickness of the solid electrolyte layer 50 at the central portion 56b. This makes it possible to increase the thickness of the solid electrolyte layer 50 at the end of the anode 10 where the solid electrolyte layer 50 is likely to become thin and is also likely to be subjected to stress, thereby reducing leakage current at the end of the anode 10. In addition, it is possible to prevent the conductive adhesive from protruding from above the cathode 40.

[0057] Each of the outer peripheral portions 55a, 55b includes a protrusion 51a, 51b along the mask layer 30 and a U-shaped portion 57a, 57b that is a roughly U-shaped portion along the tip surface 10a and side surfaces 10e, 10f of the anode 10, and the thickness of the protrusions 51a, 51b is greater than the thickness of the U-shaped portions 57a, 57b, respectively. Each U-shaped portion 57a, 57b has a cross-sectional shape similar to that of the convex portions 51a, 51b, respectively, and has an arc-shaped surface when viewed in a cross-section perpendicular to the extension direction, but may also have a trapezoidal or triangular surface. In this manner, since the remaining portions 52a, 52b have the U-shaped portions 57a, 57b, respectively, in the solid electrolytic capacitor element 2, the thickness of the solid electrolyte layer 50 in the remaining portions 52a, 52b is the maximum thickness of the U-shaped portions 57a, 57b, respectively.

[0058] FIG. 9 is a cross-sectional view that illustrates a schematic example of a solid electrolytic capacitor element according to still another embodiment of the present invention.

[0059] 9, similarly to the case of the solid electrolytic capacitor element 1, the solid electrolyte layer 50 has a protruding portion 51a and a remaining portion 52a which is a flat portion on one main surface 10c side of the anode 10, and has a protruding portion 51b and a remaining portion 52b which is a flat portion on the other main surface 10d side of the anode 10. Therefore, in the solid electrolytic capacitor element 3, the thickness of the solid electrolyte layer 50 in each of the remaining portions 52a, 52b is the thickness of the flat portion.

[0060] On the other hand, in the solid electrolytic capacitor element 3, the conductive layer 60 has, on one main surface 10c side of the anode 10, a convex portion 61a along the tip surface 10a of the anode 10 and a remainder 62a excluding the convex portion 61a, and, on the other main surface 10d side of the anode 10, a convex portion 61b along the tip surface 10a of the anode 10 and a remainder 62b excluding the convex portion 61b.

[0061] The protrusions 61a and 61b are thick film portions in which the conductive layer 60 is partially thickened, and are formed linearly (in a band shape) parallel to the tip surface 10a of the anode 10. That is, the protrusions 61a and 61b are linear protruding stripes. Here, the protrusions 61a, 61b have an arc-shaped surface when viewed in cross section in a direction perpendicular to the tip surface 10a of the anode 10, as shown in Figure 9, but may also have a trapezoidal or triangular surface.

[0062] In addition, in the solid electrolytic capacitor element 3, the entire cathode 40 including the solid electrolyte layer 50 and the conductive layer 60 has, on each of the main surfaces 10c, 10d of the anode 10, a first convex portion (convex stripe portion) along the mask layer 30, a second convex portion (convex stripe portion) along the tip surface 10a of the anode 10, and a flat portion excluding the first and second convex portions, and the thicknesses of the first and second convex portions are greater than the thickness of the flat portion.

[0063] [Method of manufacturing solid electrolytic capacitor element] The solid electrolytic capacitor elements 1 to 3 can be produced by the following method.

[0064] Fig. 10 is a schematic diagram showing an example of a process of immersing an anode on which a mask layer has been formed in a treatment liquid containing a solid electrolyte. Fig. 11 is a schematic diagram showing an example of a process of pulling an anode out of the treatment liquid and drying the treatment liquid. Fig. 12 is a schematic diagram showing another example of a process of pulling an anode out of the treatment liquid and drying the treatment liquid. Fig. 13 is a plan view showing an example of a solid electrolytic capacitor element after a solid electrolyte layer is formed through the drying step shown in Fig. 11. Fig. 14 is a plan view showing an example of a solid electrolytic capacitor element after a solid electrolyte layer is formed through the drying step shown in Fig. 12.

[0065] 10, first, the anode 10 having the mask layer 30 formed on the dielectric layer 20 is immersed in a treatment liquid 70 containing a solid electrolyte from the front end surface 10a side until it comes into contact with the mask layer 30 (first step). The treatment liquid 70 is supplied to a treatment tank 75. Next, the anode 10 is pulled out of the treatment liquid 70, and the treatment liquid 70 is dried (second step). In the second step, the anode 10 is dried in a state in which it is turned upside down from when it was immersed, as shown in Fig. 11 or 12. That is, the anode 10 is dried with the tip end surface 10a of the anode 10 facing up and the base end surface 10b of the anode 10 facing down. This makes it possible to form solid electrolyte layer 50 having convex portions 51 along mask layer 30, as shown in FIG. 13 or 14, and makes it possible to make the maximum thickness of solid electrolyte layer 50 at convex portions 51 greater than the thickness of solid electrolyte layer 50 at remaining portions 52.

[0066] More specifically, as shown in FIG. 13, the solid electrolyte layer 50 is formed so as to be selectively thicker in the area adjacent to the mask layer 30 due to gravity, or as shown in FIG. 14, the solid electrolyte layer 50 is formed so as to be thicker only in the outer peripheral portion 55 due to the coffee ring effect. Which manner of formation is used depends on the properties of treatment liquid 70, such as the viscosity, surface tension, and contact angle; in the case shown in FIG. 11, remaining portion 52 can be a flat portion as shown in FIG. 13, while in the case shown in FIG. 12, it is possible to make the thickness of solid electrolyte layer 50 at outer circumferential portion 55 greater than the thickness of solid electrolyte layer 50 at central portion 56 as shown in FIG. 14.

[0067] The first step and the second step may be alternately performed multiple times in this order. In this case, it is preferable to dry the anode 10 in a state in which it is inverted upside down from when it was immersed in at least one of the multiple second steps, and it is more preferable to dry the anode 10 in a state in which it is inverted upside down from when it was immersed in each of the multiple second steps. This embodiment is suitable when the inner and outer layers of the solid electrolyte layer 50 are formed separately, as described above.

[0068] The treatment liquids in which the anode 10 is immersed in the first step multiple times may be the same type of treatment liquid or different types of treatment liquids.

[0069] After the second step, the anode 10 from which the treatment liquid 70 has been dried is immersed in a conductive paste from the tip surface side until it comes into contact with, for example, the protrusion 51 (the area thereof not reaching the thickest part 53) (third step). Thereafter, the anode 10 is pulled out of the conductive paste, and the conductive paste is dried (fourth step). This forms a conductive layer 60 having a substantially uniform thickness as shown in Figures 2 and 7, or a conductive layer 60 having a protrusion along the tip surface 10a of the anode 10 as shown in Figure 9.

[0070] A more detailed description will be given below of a method for manufacturing the solid electrolytic capacitor element 1. In the following example, a method for simultaneously manufacturing a plurality of solid electrolytic capacitor elements using a large valve metal substrate will be described.

[0071] FIG. 15 is a schematic diagram showing an example of a step of preparing a valve metal substrate having a mask layer formed thereon.

[0072] As shown in Fig. 15, a valve metal base 11A having a dielectric layer 20 on its surface is prepared. The valve metal base 11A includes a plurality of element portions 12 and a support portion 13. Each element portion 12 has a rectangular shape and protrudes from the support portion 13. In addition, a mask layer 30 is formed on the dielectric layer 20 of each element portion 12.

[0073] First, the valve metal substrate 11A having a porous portion on its surface is cut by laser processing, punching processing, or the like, to form a shape including a plurality of element portions 12 and support portions 13.

[0074] Next, a mask layer 30 is formed on both main surfaces and both side surfaces of each element portion 12 so as to extend along the short sides of the element portion 12 .

[0075] Thereafter, the valve metal base 11A is anodized to form an oxide film that will become the dielectric layer 20 on the surface of the valve metal base 11A. At this time, an oxide film is also formed on the side surfaces of the element portions 12 that have been cut by laser processing, punching, or the like. A chemical foil on which an oxide of the valve metal has already been formed may be used as the valve metal base 11A. In this case, an oxide film is also formed on the side surfaces of the cut element portions 12 by anodizing the valve metal base 11A after cutting.

[0076] FIG. 16 is a schematic diagram showing an example of a process for forming a solid electrolyte layer.

[0077] A solid electrolyte layer 50 (see FIG. 5, etc.) is formed on the dielectric layer 20 of the element section 12. As shown in FIG. 16, it is preferable to apply a treatment liquid containing a solid electrolyte to the valve metal base 11A by a dipping method. FIG. 16 shows a state in which a treatment liquid 70 containing a solid electrolyte is supplied to a treatment tank 75.

[0078] As the treatment liquid 70 containing a solid electrolyte, for example, a dispersion liquid of a conductive polymer is used. The dispersion liquid of the conductive polymer can be applied to the outer surface of the dielectric layer 20 and dried to form a conductive polymer film. Alternatively, as the treatment liquid 70 containing a solid electrolyte, a liquid containing a polymerizable monomer, for example, 3,4-ethylenedioxythiophene and an oxidizing agent may be used. The liquid containing the polymerizable monomer can be applied to the outer surface of the dielectric layer 20 to form a conductive polymer film by chemical polymerization. This conductive polymer film becomes the solid electrolyte layer 50.

[0079] As shown in Fig. 16, the valve metal base 11A is immersed in the treatment liquid 70, so that the treatment liquid 70 permeates the porous portion of the valve metal base 11A. After immersion for a predetermined time, the valve metal base 11A is pulled out of the treatment liquid 70 and dried at a predetermined temperature for a predetermined time. The solid electrolyte layer 50 is formed by repeating the immersion in the treatment liquid 70, pulling out, and drying a predetermined number of times. At least once, and preferably all, of the drying steps, the treatment liquid 70 is dried in a state in which the valve metal base 11A is upside down compared to when it was immersed, i.e., with the element portion 12 on top and the support portion 13 on the bottom.

[0080] For example, the valve metal substrate 11A is immersed in a first dispersion liquid containing a conductive polymer, and then pulled out, and the valve metal substrate 11A is dried in a state in which it is turned upside down from when it was immersed, to form a first solid electrolyte layer. The immersion in the first dispersion liquid, the pulling out, and the drying may be performed multiple times.

[0081] After the first solid electrolyte layer is formed, the valve metal substrate 11A may be immersed in a solution containing a primer compound, pulled out, and dried to form a primer layer.

[0082] Thereafter, the valve action metal substrate 11A is immersed in a second dispersion liquid containing a conductive polymer and then pulled out, and the valve action metal substrate 11A is dried in a state in which it is inverted from when it was immersed, thereby forming a second solid electrolyte layer.

[0083] The solid electrolyte layer formed by the above method includes a first solid electrolyte layer provided on the dielectric layer, and a second solid electrolyte layer provided on the first solid electrolyte layer.

[0084] The valve metal substrate 11A is washed with pure water to remove excess primer compound. After washing, a drying process is performed. In this manner, the solid electrolyte layer 50 is formed in a predetermined region.

[0085] After the solid electrolyte layer 50 is formed, the valve metal substrate 11A is immersed in the carbon paste, pulled out, and dried to form a carbon layer in a predetermined region.

[0086] After the carbon layer is formed, the valve metal substrate 11A is immersed in a conductive paste containing metal particles, such as silver paste, and then pulled out and dried to form a cathode conductor layer in a predetermined region.

[0087] Then, the valve metal base 11A is cut to separate the element portion 12, and a rectangular anode 10 is formed, with the cut surface serving as the base end surface 10b.

[0088] Through the above steps, solid electrolytic capacitor elements 1 to 3 are obtained.

[0089] [Solid electrolytic capacitor] An example of a solid electrolytic capacitor including the solid electrolytic capacitor element of the present invention will be described below. The solid electrolytic capacitor element of the present invention may be included in a solid electrolytic capacitor having another configuration. For example, a lead frame may be used as an external electrode. The solid electrolytic capacitor of the present invention may also include a solid electrolytic capacitor element other than the solid electrolytic capacitor element of the present invention.

[0090] Fig. 17 is a perspective view showing an example of a solid electrolytic capacitor according to an embodiment of the present invention, and Fig. 18 is a cross-sectional view taken along line ZZ of the solid electrolytic capacitor shown in Fig. 17.

[0091] 17 and 18, the length direction of solid electrolytic capacitor 100 and exterior body 110 is indicated by L, the width direction by W, and the height direction by T. Here, the length direction L, the width direction W, and the height direction T are perpendicular to each other.

[0092] 17 and 18, solid electrolytic capacitor 100 has a substantially rectangular parallelepiped outer shape. Solid electrolytic capacitor 100 includes exterior body 110, first external electrode 120, second external electrode 130, and a plurality of solid electrolytic capacitor elements 1.

[0093] Exterior body 110 encapsulates a plurality of solid electrolytic capacitor elements 1. That is, a plurality of solid electrolytic capacitor elements 1 are embedded in exterior body 110. However, exterior body 110 may encapsulate one solid electrolytic capacitor element 1. That is, one solid electrolytic capacitor element 1 may be embedded inside exterior body 110.

[0094] The exterior body 110 has a substantially rectangular parallelepiped outer shape. The exterior body 110 has a first main surface 110a and a second main surface 110b that face each other in a height direction T, a first side surface 110c and a second side surface 110d that face each other in a width direction W, and a first end surface 110e and a second end surface 110f that face each other in a length direction L.

[0095] As described above, exterior body 110 has a substantially rectangular parallelepiped outer shape, but it is preferable that corners and ridges are rounded. A corner is a portion where three faces of exterior body 110 intersect, and a ridge is a portion where two faces of exterior body 110 intersect.

[0096] The exterior body 110 is made of, for example, a sealing resin.

[0097] The sealing resin contains at least a resin, and preferably contains a resin and a filler.

[0098] As the resin, an epoxy resin, a phenol resin, a polyimide resin, a silicone resin, a polyamide resin, a liquid crystal polymer, or the like is preferably used.

[0099] As the filler, silica particles, alumina particles, etc. are preferably used.

[0100] As the sealing resin, a material containing a solid epoxy resin, a phenolic resin, and silica particles is preferably used.

[0101] When a solid sealing resin is used, a resin mold such as compression molding or transfer molding is preferably used, and compression molding is more preferably used. When a liquid sealing resin is used, a molding method such as a dispensing method or a printing method is preferably used. Among them, it is preferable to form the exterior body 110 by sealing the periphery of the solid electrolytic capacitor element 1 with the sealing resin by compression molding.

[0102] The exterior body 110 may be composed of a substrate and a sealing resin provided on the substrate. The substrate is, for example, an insulating resin substrate such as a glass epoxy substrate. In this case, the bottom surface of the substrate constitutes the second main surface 110b of the exterior body 110. The thickness of the substrate is, for example, 100 μm.

[0103] The multiple solid electrolytic capacitor elements 1 are stacked in the height direction T via the conductive adhesive 140. The extending direction of each of the multiple solid electrolytic capacitor elements 1 is approximately parallel to the first main surface 110a and the second main surface 110b of the exterior body 110. The solid electrolytic capacitor elements 1 are bonded to each other via the conductive adhesive 140.

[0104] The conductive adhesive 140 is provided in the area sandwiched between the remaining portions 52 of the solid electrolyte layers 50 of adjacent solid electrolytic capacitor elements 1, and in order to reduce the thickness of the outer casing 110 (the thickness of the solid electrolytic capacitor 100), it is preferable that the conductive adhesive 140 does not cover the thickest portions 53 of the solid electrolyte layers 50 of adjacent solid electrolytic capacitor elements 1, and it is preferable that the conductive adhesive 140 is not provided over the entire area sandwiched between the protrusions 51 of the solid electrolyte layers 50 of adjacent solid electrolytic capacitor elements 1.

[0105] The conductive adhesive 140 contains, for example, metal particles such as gold, silver, copper, platinum, or the like, and resin, but here, silver is used as the metal particles and acrylic resin is used as the resin. Other examples of the resin contained in the conductive adhesive 140 include urethane resin, epoxy resin, polyimide resin, and phenol resin.

[0106] The first external electrode 120 is provided on a first end surface 110e of the exterior body 110. In Fig. 17, the first external electrode 120 is provided from the first end surface 110e of the exterior body 110 to each of the first main surface 110a, the second main surface 110b, the first side surface 110c, and the second side surface 110d. The first external electrode 120 is electrically connected to the conductive layer 60 of the cathode 40 of the solid electrolytic capacitor element 1 exposed from the exterior body 110 at the first end surface 110e. The first external electrode 120 may be directly or indirectly connected to the conductive layer 60 at the first end surface 110e of the exterior body 110.

[0107] The second external electrode 130 is provided on the second end surface 110f of the exterior body 110. In FIG. 17, the second external electrode 130 is provided from the second end surface 110f of the exterior body 110 to each of the first main surface 110a, the second main surface 110b, the first side surface 110c, and the second side surface 110d. The second external electrode 130 is electrically connected to the anode 10 (valve metal base 11) of the solid electrolytic capacitor element 1 exposed from the exterior body 110 at the second end surface 110f. The second external electrode 130 may be directly or indirectly connected to the anode 10 (valve metal base 11) at the second end surface 110f of the exterior body 110.

[0108] It is preferable that the first external electrode 120 and the second external electrode 130 are each formed by at least one method selected from the group consisting of a dip coating method, a screen printing method, a transfer method, an inkjet printing method, a dispensing method, a spray coating method, a brush coating method, a drop casting method, an electrostatic painting method, a plating method, and a sputtering method.

[0109] The first external electrode 120 preferably has a resin electrode layer containing a conductive component and a resin component. When the first external electrode 120 contains a resin component, the adhesion between the first external electrode 120 and the sealing resin of the exterior body 110 is improved, thereby improving reliability.

[0110] The second external electrode 130 preferably has a resin electrode layer containing a conductive component and a resin component. When the second external electrode 130 contains a resin component, the adhesion between the second external electrode 130 and the sealing resin of the exterior body 110 is improved, thereby improving reliability.

[0111] The conductive component preferably contains, as a main component, a metal such as silver, copper, nickel, or tin, or an alloy containing at least one of these metals.

[0112] The resin component preferably contains an epoxy resin, a phenolic resin, or the like as a main component.

[0113] The resin electrode layer is formed by, for example, a dip coating method, a screen printing method, a transfer method, an inkjet printing method, a dispensing method, a spray coating method, a brush coating method, a drop casting method, an electrostatic coating method, or the like. Among them, the resin electrode layer is preferably a printed resin electrode layer formed by applying a conductive paste by a screen printing method. When the resin electrode layer is formed by applying a conductive paste by a screen printing method, the first external electrode 120 and the second external electrode 130 are more likely to be flat than when the resin electrode layer is formed by applying a conductive paste by a dip coating method. That is, the thickness of the first external electrode 120 and the second external electrode 130 is more likely to be uniform.

[0114] When the first external electrode 120 has a resin electrode layer, the first external electrode 120 and the cathode conductor layer both contain a resin component, which increases the adhesion between the first external electrode 120 and the cathode conductor layer, thereby improving reliability.

[0115] At least one of the first external electrode 120 and the second external electrode 130 may have a so-called plating layer formed by a plating method. Examples of the plating layer include a zinc-silver-nickel layer, a silver-nickel layer, a nickel layer, a zinc-nickel-gold layer, a nickel-gold layer, a zinc-nickel-copper layer, and a nickel-copper layer. On these plating layers, for example, a copper plating layer, a nickel plating layer, and a tin plating layer are preferably provided in this order (or with the exception of some plating layers).

[0116] At least one of the first external electrode 120 and the second external electrode 130 may have both a resin electrode layer and a plating layer. For example, the second external electrode 130 may have a resin electrode layer connected to the anode 10 (valve metal substrate 11) and an outer plating layer provided on the surface of the resin electrode layer. The second external electrode 130 may also have an inner plating layer connected to the anode 10 (valve metal substrate 11), a resin electrode layer provided so as to cover the inner plating layer, and an outer plating layer provided on the surface of the resin electrode layer.

[0117] FIG. 19 is a cross-sectional view illustrating an example of a solid electrolytic capacitor according to another embodiment of the present invention.

[0118] In solid electrolytic capacitor 200 shown in FIG. 19, instead of multiple solid electrolytic capacitor elements 1, multiple solid electrolytic capacitor elements 2 are stacked in height direction T with conductive adhesive 140 interposed therebetween.

[0119] FIG. 20 is a cross-sectional view illustrating a schematic example of a solid electrolytic capacitor according to still another embodiment of the present invention.

[0120] In a solid electrolytic capacitor 300 shown in FIG. 20, instead of a plurality of solid electrolytic capacitor elements 1, a plurality of solid electrolytic capacitor elements 3 are stacked in the height direction T with conductive adhesive 140 interposed therebetween. EXAMPLES

[0121] Hereinafter, examples will be given that more specifically disclose the solid electrolytic capacitor element, the solid electrolytic capacitor, and the method for manufacturing the solid electrolytic capacitor element of the present invention, although the present invention is not limited to these examples.

[0122] (Example 1-1) An aluminum foil having an etching layer on its surface was prepared as an anode (valve metal substrate), and anodized by immersing it in an aqueous solution of ammonium adipate to form a dielectric layer on the surface of the aluminum foil.

[0123] Next, a composition consisting of a soluble polyimide siloxane and an epoxy resin was transferred by roller onto the anode on which the dielectric layer had been formed, thereby forming mask layers on both main surfaces and both side surfaces of the anode via the dielectric layer.

[0124] Next, the element was immersed in an aqueous dispersion of PEDOT:PSS up to just below the mask layer, and then pulled up, and dried in a state in which it was upside down from the immersion direction, forming a solid electrolyte layer on the dielectric layer. As shown in FIG. 2, the solid electrolyte layer had convex parts along the mask layer on both main surfaces of the anode, and the remaining parts were flat. The maximum thickness of the solid electrolyte layer in the convex parts was 25 μm, and the thickness of the solid electrolyte layer in the remaining parts excluding the convex parts, especially on the tip side of the anode, was 5 μm. In addition, the thickness of the obtained element just below the mask layer, i.e., the thickness at the thickest part of the convex parts, was 170 μm, and the thickness of the obtained element at the lower end, i.e., the thickness on the tip side of the anode, was 130 μm.

[0125] Furthermore, the element was immersed in carbon paste up to a position that did not overlap the thickest part of the solid electrolyte layer directly below the mask layer, i.e., the thickest part of the convex portion, and then pulled up, and dried in the same direction as the immersion to form a carbon layer. Thereafter, the element was immersed in silver paste in the same manner as the carbon layer to form a silver layer as a cathode conductor layer, thereby forming a conductive layer, and a solid electrolytic capacitor element was obtained. The thickness of the obtained solid electrolytic capacitor element directly below the mask layer (thickness at the thickest part of the convex portion of the solid electrolyte layer) was 170 μm, and the thickness of the lower end of the obtained solid electrolytic capacitor element (thickness at the tip side of the anode) was 160 μm.

[0126] Four of the obtained solid electrolytic capacitor elements were laminated using a conductive adhesive to obtain a laminate. The laminate was then sealed using epoxy resin and cut into pieces using a dicer. Next, a silver paste containing a resin component was screen-printed on the cathode and anode end faces of the cut-out exterior body (sealing body) to form external electrodes on the cathode and anode, thereby obtaining a finished solid electrolytic capacitor. The thickness of the obtained finished solid electrolytic capacitor in the height direction was 1110 μm.

[0127] Comparative Example 1 A finished solid electrolytic capacitor was obtained in the same manner as in Example 1-1, except that the solid electrolyte layer was not dried by turning it upside down. At this time, the thickness of the obtained solid electrolytic capacitor element directly below the mask layer was 125 μm, the thickness of the lower end of the obtained solid electrolytic capacitor element (thickness of the tip side of the anode) was 200 μm, and the thickness excluding the conductive layer (carbon layer and silver layer) of the lower end was 170 μm. In addition, the thickness in the height direction of the finished solid electrolytic capacitor was 1230 μm.

[0128] (Example 1-2) In Example 1-1, a completed solid electrolytic capacitor was obtained in the same manner, except that the conductive layer (carbon layer and silver layer) was formed to a position overlapping the thickest part of the solid electrolyte layer immediately below the mask layer. At this time, the thickness of the obtained solid electrolytic capacitor element immediately below the mask layer (thickness at the thickest part of the protruding part of the solid electrolyte layer) was 190 μm, the thickness excluding the conductive layer (carbon layer and silver layer) immediately below the mask layer was 170 μm, the thickness of the lower end (thickness at the tip side of the anode) of the obtained solid electrolytic capacitor element was 160 μm, and the thickness excluding the conductive layer (carbon layer and silver layer) at the lower end was 130 μm. In addition, the thickness in the height direction of the completed solid electrolytic capacitor was 1190 μm.

[0129] In Examples 1-1 and 1-2 and Comparative Example 1, the thickness of the finished product is the sum of the thickness of the four elements, the thickness of the conductive adhesive 30 μm, the thickness of the epoxy resin 400 μm, and the thickness of the external electrodes 20 μm.

[0130] The solid electrolytic capacitors obtained in Examples 1-1 and 1-2 and Comparative Example 1 were evaluated for the thickness in the height direction of the finished product, the withstand voltage, and short circuits after a reflow test. The results are shown in Table 1 below.

[0131] [Table 1]

[0132] In Examples 1-1 and 1-2, the thickness of the solid electrolyte layer directly below the mask layer was thick, and therefore the withstand voltage and resistance to stress during reflow were improved compared to Comparative Example 1. Furthermore, in Example 1-1, the thickest part of the solid electrolyte layer was not covered with the conductive layer (carbon layer and silver layer), and therefore the thickness of the finished product could be reduced compared to Example 1-2.

[0133] (Example 2-1) An aluminum foil having an etching layer on its surface was prepared as an anode (valve metal substrate), and anodized by immersing it in an aqueous solution of ammonium adipate to form a dielectric layer on the surface of the aluminum foil.

[0134] Next, mask layers were formed on both main surfaces and both side surfaces of the anode.

[0135] Next, the element was immersed in a mixture of paratoluenesulfonate iron (III), 3,4-ethylenedioxythiophene, and 1-butanol up to just below the mask layer, and then pulled up and dried in a state in which it was turned upside down from the immersion direction, forming a solid electrolyte layer on the dielectric layer. As shown in FIG. 7, the solid electrolyte layer had an outer peripheral portion including a convex portion along the mask layer and a central portion surrounded by the outer peripheral portion and thinner than the outer peripheral portion, on both main surfaces of the anode. The maximum thickness of the solid electrolyte layer at the convex portion of the outer peripheral portion was 20 μm, the thickness of the solid electrolyte layer at the tip side portion of the outer peripheral portion of the anode was 10 μm, and the thickness of the solid electrolyte layer at the central portion was 5 μm. In addition, the thickness of the obtained element just below the mask layer, i.e., the thickness at the thickest portion of the convex portion, was 160 μm, the thickness of the lower end portion of the obtained element, i.e., the thickness at the tip side of the anode, was 140 μm, and the thickness of the central portion of the obtained element was 130 μm.

[0136] Furthermore, the element was immersed in carbon paste up to a position that did not overlap the thickest part of the solid electrolyte layer directly below the mask layer, i.e., the thickest part of the convex portion, and then pulled up, and dried in the same direction as the immersion to form a carbon layer. Thereafter, the element was immersed in silver paste in the same manner as the carbon layer to form a silver layer as a cathode conductor layer, thereby forming a conductive layer, and a solid electrolytic capacitor element was obtained. The thickness of the obtained solid electrolytic capacitor element directly below the mask layer (thickness at the thickest part of the convex portion of the solid electrolyte layer) was 160 μm, the thickness of the lower end of the obtained solid electrolytic capacitor element (thickness at the tip side of the anode) was 160 μm, and the thickness of the central part of the obtained solid electrolytic capacitor element was 150 μm.

[0137] Four of the obtained solid electrolytic capacitor elements were laminated using a conductive adhesive to obtain a laminate. The laminate was then sealed using epoxy resin and cut into pieces using a dicer. Next, a silver paste containing a resin component was screen-printed on the cathode and anode end faces of the cut-out exterior body (sealing body) to form external electrodes on the cathode and anode, thereby obtaining a finished solid electrolytic capacitor. The thickness of the obtained finished solid electrolytic capacitor in the height direction was 1070 μm.

[0138] Comparative Example 2 A finished solid electrolytic capacitor was obtained in the same manner as in Example 2-1, except that the solid electrolyte layer was not dried upside down. At this time, the thickness of the obtained solid electrolytic capacitor element directly below the mask layer was 125 μm, the thickness of the lower end of the obtained solid electrolytic capacitor element (thickness of the tip side of the anode) was 190 μm, and the thickness excluding the conductive layer (carbon layer and silver layer) of the lower end was 160 μm. In addition, the thickness in the height direction of the finished solid electrolytic capacitor was 1190 μm.

[0139] (Example 2-2) In Example 2-1, a completed solid electrolytic capacitor was obtained in the same manner, except that the conductive layer (carbon layer and silver layer) was formed to a position overlapping the thickest part of the solid electrolyte layer immediately below the mask layer. At this time, the thickness of the obtained solid electrolytic capacitor element immediately below the mask layer (thickness at the thickest part of the protruding part of the solid electrolyte layer) was 180 μm, the thickness excluding the conductive layer (carbon layer and silver layer) immediately below the mask layer was 160 μm, the thickness of the lower end (thickness of the tip side of the anode) of the obtained solid electrolytic capacitor element was 160 μm, the thickness excluding the conductive layer (carbon layer and silver layer) at the lower end was 140 μm, the thickness of the central part of the obtained solid electrolytic capacitor element was 150 μm, and the thickness excluding the conductive layer (carbon layer and silver layer) at the central part was 130 μm. In addition, the thickness in the height direction of the completed solid electrolytic capacitor was 1150 μm.

[0140] In Examples 2-1 and 2-2 and Comparative Example 2, the thickness of the finished product is the sum of the thickness of the four elements, the thickness of the conductive adhesive 30 μm, the thickness of the epoxy resin 400 μm, and the thickness of the external electrodes 20 μm.

[0141] The solid electrolytic capacitors obtained in Examples 2-1 and 2-2 and Comparative Example 2 were evaluated for the thickness in the height direction of the finished product, the withstand voltage, and short circuits after a reflow test. The results are shown in Table 2 below.

[0142] [Table 2]

[0143] In Examples 2-1 and 2-2, the thickness of the solid electrolyte layer under the mask layer was thick, and therefore the resistance to pressure and stress during reflow was increased compared to Comparative Example 2. In Example 2-1, the thickest part of the solid electrolyte layer was not covered with the conductive layer (carbon layer and silver layer), and therefore the thickness of the finished product could be further reduced compared to Example 2-2. [Explanation of symbols]

[0144] 1, 2, 3 Solid electrolytic capacitor element 10 Anode 10a Tip surface 10b Proximal surface 10c, 10d main surface 10e, 10f Side 11, 11A Valve metal substrate 12 Element section 13 Support part 20 Dielectric layer 30 Mask Layer 40 cathode 50 Solid electrolyte layer 51a, 51b, 51 convex part 52a, 52b, 52 remainder 53a, 53b, 53 thickest part 54 Proximal end 55a, 55b, 55 outer periphery 56a, 56b, 56 center part 57a, 57b U-shaped part 60 Conductive Layer 61a, 61b Convex portion 62a, 62b remainder 70 Processing fluid 75 Treatment tank 100, 200, 300 Solid electrolytic capacitors 110 Exterior body 110a 1st main surface 110b 2nd principal surface 110c 1st side 110d 2nd side 110e 1st end face 110f 2nd end face 120 1st external electrode 130 2nd external electrode 140 Conductive adhesive t1, t2 Maximum thickness of the solid electrolyte layer at the convex part Tmax The thickness of the solid electrolytic capacitor element at its thickest point

Claims

1. an anode comprised of a valve metal substrate and having a distal end surface and a proximal end surface; a dielectric layer provided on at least one of the main surfaces of the anode, excluding at least the base end surface; a mask layer formed of an insulating material and disposed on the dielectric layer along the base end surface; a cathode provided on the dielectric layer on the tip surface side of the mask layer, the cathode has a solid electrolyte layer provided on the dielectric layer and a conductive layer provided on the solid electrolyte layer, the solid electrolyte layer has a protrusion along the mask layer, a maximum thickness of the solid electrolyte layer at the protruding portion is greater than a thickness of the solid electrolyte layer in a remaining portion excluding the protruding portion.

2. 2 . The solid electrolytic capacitor element according to claim 1 , wherein a region from the thickest portion of the protrusion to a base end of the solid electrolyte layer located on the base end face side of the anode is not covered with the conductive layer.

3. The solid electrolytic capacitor element according to claim 2 , wherein a thickness of the solid electrolytic capacitor element in the remaining portion does not exceed a thickness of the solid electrolytic capacitor element in the thickest portion.

4. 4. The solid electrolytic capacitor element according to claim 1, wherein the remaining portion is a flat portion.

5. the solid electrolyte layer has an outer circumferential portion including the protrusion and a central portion surrounded by the outer circumferential portion, 4. The solid electrolytic capacitor element according to claim 1, wherein the thickness of the solid electrolyte layer in the outer circumferential portion is greater than the thickness of the solid electrolyte layer in the central portion.

6. A solid electrolytic capacitor comprising a laminate in which a plurality of solid electrolytic capacitor elements according to any one of claims 1 to 3 are laminated.

7. A method for producing a solid electrolytic capacitor element according to any one of claims 1 to 3, comprising the steps of: a first step of immersing the anode having the mask layer formed on the dielectric layer in a treatment liquid containing a solid electrolyte from the front end surface side until the front end surface contacts the mask layer; a second step of removing the anode from the treatment solution and drying the treatment solution, In the second step, the anode is dried in a state in which it is turned upside down from when it was immersed.

8. The first step and the second step are alternately performed in this order multiple times, The method for producing a solid electrolytic capacitor element according to claim 7 , wherein in at least one of the second steps which are performed a plurality of times, the anode is dried in a state in which it is turned upside down from when it was immersed.

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