Electrode leading-out method and packaging method for tantalum electrolytic capacitor

Abstract

Disclosed is an electrode leading-out method and packaging method for a tantalum electrolytic capacitor. The electrode leading-out method includes the following steps: S1, fabricating an insulating protective layer outside an electrode body of the tantalum electrolytic capacitor; S2, exposing a cathode leading-out part on a cathode pre-leading-out part, and exposing a tantalum core leading-out end in an area where a terminal of a tantalum core is located; S3, depositing a metal layer on each of the cathode leading-out part and the tantalum core leading-out end which are exposed; and S4, fabricating an outer electrode for mounting on each of the metal layer of the cathode leading-out part and the metal layer of the tantalum core leading-out end so as to respectively lead out a cathode and an anode.

Claims

1. An electrode leading-out method for a tantalum electrolytic capacitor, comprising the following steps: S1, fabricating an insulating protective layer outside an electrode body of the tantalum electrolytic capacitor; S2, exposing a cathode leading-out part on a cathode pre-leading-out part, and exposing a tantalum core leading-out end in an area where a terminal of a tantalum core is located; and S3, fabricating an outer electrode for mounting, on each of the cathode leading-out part and the tantalum core leading-out end, so as to respectively lead out a cathode and an anode, or depositing a metal layer on each of the cathode leading-out part and the tantalum core leading-out end which are exposed, and fabricating an outer electrode for mounting, on each of the metal layers, so as to respectively lead out a cathode and an anode; wherein before the insulating protective layer is fabricated in step S1, a conductive bearing substrate is adhered to the cathode pre-leading-out part at the bottom of a cathode layer in advance by using a conductive adhesive; and correspondingly, in step S2, the cathode leading-out part is exposed by peeling off the insulating protective layer on the cathode pre-leading-out part, and the exposed cathode leading-out part is at least partial bottom of the conductive bearing substrate.

2. The electrode leading-out method for the tantalum electrolytic capacitor of claim 1, wherein the conductive bearing substrate is a metal substrate or a nonmetal substrate with dual sides being printed with electrode patterns, wherein the dual-sided electrode patterns of the nonmetal substrate are connected and conducted by grouting via a pre-buried hole, and the at least partial bottom which is exposed comprises electrode patterns.

3. The electrode leading-out method for the tantalum electrolytic capacitor of claim 2, wherein the nonmetal substrate is one of a ceramic substrate, a glass fiber plate, an epoxy resin plate, a phenolic resin plate, a silicone rubber plate, a BCB plate, a BT resin plate, a polypropylene plate, a polycarbonate plate, a polyvinyl chloride plate, a polyfluortetraethylene plate and a polyurethane plate.

4. The electrode leading-out method for the tantalum electrolytic capacitor of claim 1, wherein the tantalum core leading-out end is located at the bottom of the electrode body, and a lower end of the electrode body is the tantalum core leading-out end, or the terminal of the tantalum core extends from one end of a tantalum core and is bent to the downside of the bottom of the tantalum core, and a bent part located below the bottom of the tantalum core is the tantalum core leading-out end.

5. The electrode leading-out method for the tantalum electrolytic capacitor of claim 4, wherein the overall cathode layer is coated by the insulating protective layer, and the tantalum core leading-out end is exposed out of the insulating protective layer.

6. The electrode leading-out method for the tantalum electrolytic capacitor of claim 5, wherein in step S2, the cathode leading-out part is exposed by peeling off the insulating protective layer on the cathode pre-leading-out part.

7. A packaging method for a tantalum electrolytic capacitor, comprising an electrode leading-out step and a packaging step, wherein the electrode leading-out method of claim 1 is adopted in the electrode leading-out step, and the packaging step is to coat a plastic packaging layer outside the insulating protective layer.

8. The packaging method for the tantalum electrolytic capacitor of claim 7, wherein after the packaging step is completed, the metal layer deposited on the tantalum core leading-out end is enabled to be flush with the surface of the plastic packaging layer.

9. An electrode leading-out method for the tantalum electrolytic capacitor, comprising the following steps: S1, fabricating an insulating protective layer outside an electrode body of the tantalum electrolytic capacitor; S2, exposing a cathode leading-out part on a cathode pre-leading-out part, and exposing a tantalum core leading-out end in an area where a terminal of a tantalum core is located; and S3, fabricating an outer electrode for mounting, on each of the cathode leading-out part and the tantalum core leading-out end, so as to respectively lead out a cathode and an anode, or depositing a metal layer on each of the cathode leading-out part and the tantalum core leading-out end which are exposed, and fabricating an outer electrode for mounting, on each of the metal layers, so as to respectively lead out a cathode and an anode; wherein in step S2, the cathode leading-out part is exposed by peeling off the insulating protective layer on the cathode pre-leading-out part, and the exposed cathode leading-out part is a part of a silver layer of the cathode.

10. A packaging method for a tantalum electrolytic capacitor, comprising an electrode leading-out step and a packaging step, wherein the electrode leading-out method of claim 9 is adopted in the electrode leading-out step, and the packaging step is to coat a plastic packaging layer outside the insulating protective layer.

11. The packaging method for the tantalum electrolytic capacitor of claim 10, wherein after the packaging step is completed, the metal layer deposited on the tantalum core leading-out end is enabled to be flush with the surface of the plastic packaging layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram showing a structure of a traditional chip-type electrolytic capacitor;

(2) FIG. 2 is a schematic diagram showing an electrode of a tantalum electrolytic capacitor in an embodiment of the present application;

(3) FIGS. 3A-3G are a schematic diagram showing an electrode leading-out method for the tantalum electrolytic capacitor as shown in FIG. 2;

(4) FIG. 4 is a schematic diagram showing an electrode of a tantalum electrolytic capacitor in another embodiment of the present application;

(5) FIGS. 5A-5D are a schematic diagram showing an electrode leading-out method for the tantalum electrolytic capacitor as shown in FIG. 4;

(6) FIGS. 6A-6D are a schematic diagram showing another electrode leading-out method for the tantalum electrolytic capacitor as shown in FIG. 4;

(7) FIGS. 7A-7C are a schematic diagram showing further electrode leading-out method for the tantalum electrolytic capacitor as shown in FIG. 4;

(8) FIG. 8 is a schematic diagram showing an electrode of a tantalum electrolytic capacitor in further embodiment of the present application; and

(9) FIGS. 9A-9E are a schematic diagram showing an electrode leading-out method for the tantalum electrolytic capacitor as shown in FIG. 8.

DETAILED DESCRIPTION

(10) The present application is further described below in conjunction with the accompanying drawings and specific implementation manners.

(11) A specific implementation manner of the present application provides an electrode leading-out method for a tantalum electrolytic capacitor. The method includes the following steps S1 to S4.

(12) S1, an insulating protective layer is fabricated outside an electrode body of the tantalum electrolytic capacitor. Referring to FIG. 2, FIG. 4 or FIG. 8, the electrode body includes a tantalum core 10 of an anode, a cathode layer 20 (a main body of the cathode layer includes a conductive polymer layer, a graphite layer and a silver layer) and a terminal 11 (or 12, 13) of the tantalum core 10. It should be noted that a dielectric layer (tantalum pentoxide) between the tantalum core 10 and the cathode layer 20 is unshown in the figures, that is, there is the dielectric layer between the tantalum core 10 and the cathode layer 20 in the accompanying drawings, they are not in contact, and the electrode leading-out part is highlighted for only simplifying the figures. On one hand, the insulating protective layer plays a role in isolating lead-out parts of a cathode and an anode, and on the other hand, it plays a role in protecting the capacitor.

(13) S2, a cathode leading-out part is exposed on a cathode pre-leading-out part, and a tantalum core leading-out end is exposed in an area where the terminal of the tantalum core is located. Referring to FIGS. 3A-3G, the cathode pre-leading-out part 50 is located on the end, opposite to the terminal of the tantalum core, on the bottom of the capacitor according to a design demand of a chip capacitor.

(14) S3, a metal layer is deposited on each of the cathode leading-out part and the tantalum core leading-out end which are exposed, for example, a metal such as copper, silver, nickel, tin, palladium, gold, platinum, tantalum and niobium is deposited.

(15) S4, an outer electrode for mounting is fabricated on each of the metal layer of the cathode leading-out part and the metal layer of the tantalum core leading-out end so as to respectively lead out a cathode and an anode. The outer electrodes on two ends are L-shaped electrodes, that is, a part of each electrode is located on an end of the capacitor, the other part is located on a position, close to the end, on the bottom of the capacitor, and the two parts are connected to form an outer electrode.

(16) In the embodiment of the present application, the terminal of the tantalum core may extend out of one end or the bottom of the tantalum core. If the terminal of the tantalum core extends out of one end of the tantalum core, the anode may be directly led out of the end by using the terminal of the tantalum core, or the anode may be led out by bending the terminal of the tantalum core to the bottom. If the terminal of the tantalum core extends out of the bottom of the tantalum core, the anode may be directly led out of the bottom. For the cathode, the cathode may be led out by adopting a conductive bearing substrate or a silver layer of a cathode body. Moreover, in the present application, the anode and the cathode are led out by indirectly or directly covering an anode leading-out end and the cathode leading-out part (a metal layer is deposited in the middle) with the outer electrodes, rather than adopting a lead welding manner.

(17) As shown in FIG. 2 which is a schematic diagram showing an electrode of a tantalum electrolytic capacitor in an embodiment of the present application, a terminal 11 of a tantalum core of the tantalum electrolytic capacitor is led out of the left end of the tantalum core 10. FIGS. 3A-3G_show an exemplary leading-out manner of the electrode as shown in FIG. 2, the leading-out process thereof is shown in FIGS. 3A-3G and includes steps (a1) to (a7).

(18) (a1) As shown in FIG. 3A, before the insulating protective layer is fabricated, a conductive bearing substrate 30 is adhered to a cathode pre-leading-out part 50 of a cathode layer in advance by using a conductive adhesive 40. The conductive adhesive 40 is, for example, a conductive silver adhesive; and the conductive bearing substrate 30 is, for example, a metal substrate or a nonmetal substrate with dual sides being printed with electrode patterns, and the dual-sided electrode patterns are connected and conducted by grouting via a pre-buried hole. In addition, the side, close to the end of the capacitor, on the bottom of the conductive bearing substrate 30 may be set to have a boss for facilitating subsequent processes of peeling-off, metal deposition and outer electrode fabrication. The nonmetal substrate may be one of a ceramic substrate, a glass fiber plate, an epoxy resin plate, a phenolic resin plate, a silicone rubber plate, a BCB plate, a BT resin plate, a polypropylene plate, a polycarbonate plate, a polyvinyl chloride plate, a polyfluortetraethylene plate and a polyurethane plate.

(19) (a2) As shown in FIG. 3B, after step (a1) is completed, an insulating layer 60 is sprayed outside the electrode body. The spraying thickness is 1 m to 200 m, preferably, the thickness is 5 m to 50 m, and a spraying material includes synthetic resin and/or a polymer material; and the overall cathode layer (including the conductive bearing substrate adhered to the bottom of the cathode layer), the exposed end of the tantalum core 10 and the root of the terminal 11 of the tantalum core are coated by the sprayed insulating layer 60.

(20) (a3) As shown in FIG. 3C, after spraying is completed, the terminal 11 of the tantalum core is bent from a root position which is not coated by the insulating layer 60 to the downside of the bottom of the tantalum core 10, and the bottom is a tantalum core leading-out end 110. It may be seen that the terminal 11 of the tantalum core is bent to the bottom and is closer to the bottom of the cathode layer, and therefore, at the moment, the insulating layer 60 favorably plays a role in avoiding the situation that the cathode and the anode are short-circuited.

(21) (a4) As shown in FIG. 3D, module packaging is performed, that is, modules after completing step (a3) are integrally packaged by adopting an existing manner and material, and how to perform packaging is not repeated herein. The overall electrode body is coated by a plastic packaging layer 70 formed by packaging, preferably, the insulating layer 60 may be exposed on the cathode pre-leading-out part 50 during packaging.

(22) (a5) As shown in FIG. 3E, peeling-off is performed, that is, the plastic packaging layer 70 (if the overall insulating layer 60 is coated by the plastic packaging layer) and the insulating layer 60 are successively peeled off on the cathode pre-leading-out part 50 to expose at least partial bottom of the conductive bearing substrate 30, that is, the cathode leading-out part; and if the conductive bearing substrate is the nonmetal substrate, the exposed bottom correspondingly includes electrode patterns. Meanwhile, the plastic packaging layer is peeled off on an area where the tantalum core leading-out end 110 is located so as to expose the tantalum core leading-out end 110.

(23) (a6) As shown in FIG. 3F, a metal layer A1 is deposited on the exposed tantalum core leading-out end 110, and a metal layer A2 is deposited on the exposed cathode leading-out part.

(24) (a7) As shown in FIG. 3G, mounting electrodes, that is, a pair of outer electrodes B1 and B2, of the capacitor are fabricated in a manner such as electroplating. During fabrication, the outer electrode B1 covers the metal layer A1, and the outer electrode B2 covers the metal layer A2, so that the outer electrodes B1 and B2 are respectively in contact connection with the metal layers A1 and A2, and then, the anode and the cathode are led out.

(25) It may be seen from the aforementioned embodiments that compared with the prior art, the electrode leading-out method in the embodiment of the present application can save a reservation space for a welding spot brought by a welding manner and ensure that the utilization ratio of the space of the capacitor is increased. Specifically, in an existing anode leading-out manner, a spacing which is 1 mm at least is required to be reserved between a welding spot area and the shoulder of a core; and in the present application, adopted is a manner that the terminal of the tantalum core is directly bent to form the tantalum core leading-out end, and then, the leading-out end is deposited with the metal and is electroplated with the outer electrodes, and therefore, the length of the root, which is required to be remained for bending, of the terminal of the tantalum core is only about 5 m to 100 m, and preferably, the length is 10 m to 50 m.

(26) As shown in FIG. 4 which is a schematic diagram showing an electrode of a tantalum electrolytic capacitor in another embodiment of the present application, a terminal 12 of a tantalum core of the tantalum electrolytic capacitor is led out of the left end of the tantalum core 10. FIGS. 5A-5D show an exemplary leading-out manner of the electrode as shown in FIG. 4, the manner is the same as that in the aforementioned embodiments, except that an anode leading-out structure is directly fabricated at the left by using the terminal 12 of the tantalum core, and accordingly, a cathode may be led out of the bottom by directly using a silver layer, rather than adopting a bearing substrate. The leading-out process is shown in FIGS. 5A-5D and includes steps (b1) to (b4).

(27) (b1) As shown in FIG. 5A, insulating spraying is performed directly on an electrode body to form an insulating layer 60.

(28) (b2) As shown in FIG. 5B, the terminal of the tantalum core is cut to make an exposed end face of the terminal flush with the surface of the insulating layer 60, so that a tantalum core leading-out end 120 is formed on the end face; in addition, the insulating layer on a cathode pre-leading-out part 50 is peeled off to expose a cathode leading-out part.

(29) (b3) As shown in FIG. 5C, the tantalum core leading-out end 120 of the anode has been flush with the insulating layer 60, and therefore, it is possible that no metal layers are deposited; and a meta layer A2 is only deposited on the cathode leading-out part, and the deposited metal layer A2 is flush with the surface of a cathode layer.

(30) (b4) As shown in FIG. 5D, outer electrodes B1 and B2 are fabricated, wherein the part, located on the end of the capacitor, of the outer electrode B1 coats the tantalum core leading-out end 120 to lead out an anode, and the part, located on the bottom of the capacitor, of the outer electrode B2 coats the metal layer A2 to lead out a cathode.

(31) FIGS. 6A-6D show another exemplary leading-out manner of the electrode as shown in FIG. 4, the leading-out process thereof is shown in FIGS. 6A-6D and includes steps (c1) to (c4). The manner is the same as that as shown in FIGS. 5A-5D, except that the terminal of the tantalum core is cut according to a certain size, then, overall packaging is performed, and the thickness of a plastic packaging layer 70 for packaging is equal to the length of the terminal, remained after cutting, of the tantalum core, that is, a cutting end face of the terminal of the tantalum core is flush with the surface of the plastic packaging layer 70.

(32) FIGS. 7A-7C show further exemplary leading-out manner of the electrode as shown in FIG. 4, the leading-out process thereof is shown in FIGS. 7A-7C and includes steps (d1) to (d3).

(33) (d1) As shown in FIG. 7A, a conductive bearing substrate 30 is adhered to a cathode pre-leading-out part at the bottom of a cathode layer by using a conductive adhesive 40, and then, an overall substrate 90 of the capacitor is fabricated below the conductive bearing substrate 30, wherein the main purpose of the substrate 90 is to ensure that the cathode dissipates heat better.

(34) (d2) As shown in FIG. 7B, module packaging is performed, the formed plastic packaging layer 70 is flush with a tantalum core leading-out end cut in advance.

(35) (d3) As shown in FIG. 7C, outer electrodes are fabricated, the outer electrode B1 covers the tantalum core leading-out end to lead out an anode, and the outer electrode B2 is connected with one side of the conductive bearing substrate to lead out a cathode.

(36) As shown in FIG. 8 which is a schematic diagram showing an electrode of a tantalum electrolytic capacitor in further embodiment of the present application, a terminal 13 of a tantalum core of the tantalum electrolytic capacitor is led out of the bottom of the tantalum core 10, and an anode will be directly led out of the bottom in the present embodiment. FIGS. 9A-9E show an exemplary leading-out manner of the electrode as shown in FIG. 8, as shown in FIGS. 9A-9E, the leading-out process includes steps (e1) to (e5).

(37) (e1) As shown in FIG. 9A, a conductive bearing substrate 30 is adhered to an area of a cathode pre-leading-out part 50 at the bottom of a cathode layer by using a conductive adhesive 40, and meanwhile, the terminal 13 of the tantalum core needs to be cut, so that the phenomenon that the terminal 13 of the tantalum core is protruded out of the conductive bearing substrate 30 in a horizontal direction to form a tantalum core leading-out end 130 is avoided.

(38) (e2) As shown in FIG. 9B, an insulating layer 60 is sprayed outside the overall electrode body formed above, the overall cathode layer (including the conductive bearing substrate) is coated by the insulating layer 60, the tantalum core leading-out end 130 is exposed only, and the tantalum core leading-out end 130 is flush with the surface of the insulating layer 60.

(39) (e3) As shown in FIG. 9C, module packaging is performed outside the insulating layer 60 to form a plastic packaging layer 70, which is similar to that in the embodiment as shown in FIG. 3D.

(40) (e4) As shown in FIG. 9D, peeling-off is performed, that is, peeling-off is performed in the same manner as the step (a5) in the embodiment as shown in FIG. 3E.

(41) (e5) As shown in FIG. 9E, metal layers are deposited, and outer electrodes are fabricated, that is, the metal layers are deposited in the same manner as the step (a6) in the embodiment as shown in FIG. 3F, and the outer electrodes are fabricated in the same manner as the step (a7).

(42) In a word, by using the electrode leading-out method provided by the present application, the utilization ratio of the space in the capacitor can be increased, and the volume of the tantalum core of the anode can be increased under the condition that the height of the capacitor is reduced or kept constant, so that the electric performance of the capacitor is improved, and the miniaturization and thickness reduction of the capacitor are further achieved.

(43) The aforementioned contents are further detailed descriptions of the present application in conjunction with the specific preferred implementation manners, but cannot affirm that the specific implementation of the present application is only limited to these descriptions. The skilled in the art to which the present application belongs may further make several equivalent replacements or obvious modifications without departing from the concept of the present application, and those of which the performances or applications are the same should be regarded to fall within the protective scope of the present application.

(44) Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.