A method for manufacturing an electrolyte capacitor including at least the following steps: placing a valve-metal anode slug with its lower side on a substrate with a non-conductive epoxy target area without solder mask, curing the non-conductive epoxy, depositing a first conductive layer on the first end-face of the valve-metal anode slug and curing the first conductive layer, forming a dielectric on the valve-metal material of the valve-metal anode slug by anodization, depositing and curing a first non-conductive layer to cover an exposed surface of the first conductive layer, depositing a MnO.sub.2 layer and an electrically conductive coating, depositing a second conductive layer on the second end-face of the valve-metal anode slug and curing the second conductive layer, overmolding, and singulating of each single capacitor and the assembled substrate.

A method for producing agglomerated tantalum particles, comprising: a step for grinding secondary tantalum particles, which are obtained by reducing a tantalum salt, and adding water thereto to give a water-containing mass; a step for drying said water-containing mass to give a dry mass; a step for sieving said dry mass to give spherical particles; and a step for heating said spherical particles. A mixed tantalum powder comprising a mixture of agglomerated tantalum particles (X) with agglomerated tantalum particles (Y), wherein said agglomerated tantalum particles (X) show a cumulative percentage of particles with particle size of 3 m or less of 5 mass % or less after 25 W ultrasonic radiation for 10 min, while said agglomerated tantalum particles (Y) show a cumulative percentage of particles with particle size of 3 m or less of 10 mass % or more after 25 W ultrasonic radiation for 10 min.

Tantalum powders produced using a tantalum fiber precursor are described. The tantalum fiber precursor is chopped or cut into short lengths having a uniform fiber thickness and favorable aspect ratio. The chopped fibers are formed into a primary powder having a controlled size and shape, narrow/tight particle size distribution, and low impurity level. The primary powder is then agglomerated into an agglomerated powder displaying suitable flowability and pressability such that pellets with good structural integrity and unifrom pellet porosity are manufacturable. The pellet is sintered and anodized to a desired formation voltage. The thusly created capacitor anode has a dual morphology or dual porosity provided by a primary porosity of the individual tantalum fibers making up the primary powder and a larger secondary porosity formed between the primary powders agglomerated into the agglomerated powder.

A wet electrolytic capacitor is provided. The capacitor comprises an anode that comprises an anodically oxidized pellet formed from a pressed and sintered valve metal powder, a cathode that comprises a metal substrate coated with a conductive coating, a microporous membrane that is positioned between the anode and cathode and contains an olefin polymer having a weight-average molecular weight of about 1,000,000 grams per mole or more, and a fluidic working electrolyte in communication with the anode and the cathode.

A sintered body obtainable by a process which includes pressing a powder comprising or consisting of at least one valve metal so as to provide a pellet, providing the pellet together with a reducing agent so that the pellet is not in a direct contact with and does not come into a direct contact with the reducing agent, heating so that the powder in the pellet is sintered to form a sintered body, an oxygen content of the at least one valve metal within the sintered body is simultaneously reduced, and the reducing agent is oxidized to an oxidized reducing agent, and removing the oxidized reducing agent with at least one mineral acid.

An improved capacitor is provided wherein the capacitor has an improved bond between the anode and anode wire. The anode comprises a pressed anode powder comprising a first density region and a second density region wherein the second density region has a higher density than the first density region. An anode wire extends into the second density region wherein the anode wire in the second density region is distorted by compression. This allows for better utilization of the metal powder surface area by allowing a lower bulk press density and lower sinter temperature while still achieving the necessary wire pull strength. In addition, this invention when utilized with deoxidation steps, results in sufficient wire pull strengths not possible otherwise.

An improved capacitor is provided wherein the capacitor has an improved bond between the anode and anode wire. The anode comprises a pressed anode powder comprising a first density region and a second density region wherein the second density region has a higher density than the first density region. An anode wire extends into the second density region wherein the anode wire in the second density region is distorted by compression. This allows for better utilization of the metal powder surface area by allowing a lower bulk press density and lower sinter temperature while still achieving the necessary wire pull strength. In addition, this invention when utilized with deoxidation steps, results in sufficient wire pull strengths not possible otherwise.

A method for manufacturing a solid electrolytic capacitor and an improved capacitor formed thereby is described. The method includes forming a dielectric on an anode at a formation voltage; forming a conductive polymer layer on the dielectric; and reforming the dielectric in a reformation electrolyte at a reformation voltage wherein the reformation electrolyte comprises a thermal degradation inhibitor.

Provided is an anode for an electrolytic device formed of a substantially uniform mixture of elongated elements with capacitor grade tantalum powders of tantalum metal. Also provided is a method for forming an anode or cathode for an electrolytic device formed of a substantially uniform mixture of elongated elements of a valve metal and a conductive powder metal.

A solid electrolytic capacitor includes a capacitor element. The capacitor element includes an anode body that is a porous sintered body, a dielectric layer disposed on a surface of the porous sintered body, an insulating material disposed on a surface of the dielectric layer, and a solid electrolyte layer disposed on a surface of the insulating material. The capacitor element has at least one corner part. An amount of the insulating material disposed in the at least one corner part of the capacitor element is larger than an amount of the insulating material disposed in a center part of the capacitor element.