Partitioned reaction container for manufacturing capacitor element including openable and closable passage

A reaction container for manufacturing a capacitor element includes a container which accommodates electrolytic solution therein, a partitioning frame which can partition the inside of the container into a plurality of individual chambers, negative electrode members individually arranged in each of the individual chambers, and a constant-current source electrically connected to the cathode members. A passage, which enables movement of the electrolytic solution between each individual chamber and at least one individual chamber of the individual chambers adjacent to each individual chamber, is provided in a manner such that the passage can be opened and closed.

TECHNICAL FIELD

The present invention relates to a reaction container for manufacturing a capacitor element capable of stably forming a uniform dielectric layer and a uniform semiconductor layer with respect to a plurality of conductive members while keeping the forming range constant, and also relates to a method of manufacturing a capacitor element.

BACKGROUND TECHNIQUE

A capacitor for use in, for example, a circuit for a CPU (Central Processing Unit) in a personal computer and the like is required to have high capacity and low ESR (Equivalent Series Resistance) to control voltage fluctuation and suppress heat generation during the passing of high ripple currents.

As a capacitor for use in a CPU circuit, an aluminum solid electrolytic capacitor and a tantalum solid electrolytic capacitor are known. As such solid electrolytic capacitor, it is known that the capacitor is constituted by one of electrodes (conductive member) made of an aluminum foil having minute pores in a surface layer or a sintered body formed by sintering tantalum powder having minute pores therein, a dielectric layer formed on the surface of the one of the electrodes, and the other electrode (typically, a semiconductor layer) formed on the dielectric layer.

As a forming method of a semiconductor layer of a capacitor in which the semiconductor layer constitutes the other electrode, methods using an energization method described in U.S. Pat. No. 1,868,722 (Patent Document 1), U.S. Pat. No. 1,985,056 (Patent Document 2), and U.S. Pat. No. 2,054,506 (Patent Document 3) are known. In all of the methods, a semiconductor layer is formed by immersing a conductive member having a dielectric layer on the surface thereof into semiconductor layer forming solution and applying voltage (passing electrical current) between the conductive member as an anode and a cathode prepared in the semiconductor layer forming solution.

Japanese Unexamined Laid-open Patent Application Publication No. 1-13-22516 (Patent Document 4) describes a method for forming a semiconductor layer by passing an electric current in which a DC bias current is superimposed on an alternating current through a conductive member having a dielectric layer. Further, Japanese Unexamined Laid-open Patent Application Publication No. H3-163816 (Patent Document 5) describes a method for forming a semiconductor layer on a chemical polymerization layer by having a conductive member come in contact with a chemical polymerization layer formed on the dielectric layer and electropolymerizing using the conductive member as an anode.

However, with the methods as described in Patent Documents 4 and 5, there were the following problems when simultaneously forming a semiconductor layer on each of a plurality of conductive members. That is, with the method described in Patent Document 4, a semiconductor layer is also formed on the cathode side and there is a problem that the formation condition of the semiconductor layer changes as the energizing time passes, and it was also difficult to evenly passing electric current through a plurality of conductive members. Further, with the method described in Patent Document 5, it is difficult to form a uniform semiconductor layer on the inside of each conductive member since energizing is conducted through a conductive member arranged on the outside and used as an anode. In the case of a large conductive member having small pores formed therein, it was especially difficult to form a uniform semiconductor layer.

In cases where a semiconductor layer is formed on the aforementioned conductive member in which a dielectric layer is formed by the energizing method, there were no problems when forming a semiconductor layer on each of a few conductive members. However, in the case of simultaneously forming a semiconductor layer on each of one hundred or more conductive members at an industrial level, since the individual conductive members are not always homogeneous, and the semiconductor forming speeds are different from each other depending on conductive members, especially when a semiconductor layer is formed simultaneously on a plurality of conductive members, the current value of the electricity flowing through each conductive member does not become constant, and it was sometimes difficult to manufacture capacitors having stable capacity since the formation condition of the semiconductor layer of the manufactured capacitor was uneven.

Therefore, the inventors proposed a reaction container having a configuration in which small reaction containers (compartments) corresponding to the individual conductive members were arranged (See Patent Documents 6 and 7).

PRIOR ART DOCUMENTS

Patent Document

SUMMARY OF THE INVENTION

Problems to be Solved by the Invention

However, in the case of using the reaction container partitioned into individual chambers as described in Patent Document 6, since the reaction liquid is independently consumed in each individual chamber and therefore attachment to the conductive member, drying, etc., progresses independently in each individual chamber, the time-dependent change of the liquid level in each compartment is not uniform, which causes a problem that the forming range of the dielectric layer or the semiconductor layer in each conductive member (anode member) cannot be maintained uniformly. Also, the density of the reaction solution differs between compartments, and there was a problem that dielectric layers and semiconductor layers with respect to each conductive member (anode member) could not be formed.

In addition, the reaction container as described in Patent Document 7 is provided with minute holes communicating adjacent compartments to adjust the liquid level in each compartment to the same height, but when, for example, chemical conversion treatment is performed using this reaction container, the potential difference between elements (between conductive members) is sometimes large especially at an initial stage, which causes the problem that electric current in the amount that cannot be ignored with respect to the homogenization of a dielectric layer leaks to other individual chambers (compartments) via the holes, or the problem that the degree of such leakage differs depending on the position of the individual chamber (compartment). As a result, the amount of electric current flowing through each conductive member varies and a uniform capacitor element cannot always be manufactured.

The present invention was made in view of the aforementioned technical backgrounds, and aims to provide a reaction container for manufacturing a capacitor element and a manufacturing method of a capacitor element, in which electrolytic reaction, such as, e.g., anodizing and electrolytic polymerization, can be performed for each conductive member disposed in each individual chamber (compartment) with a predetermined current value, and the liquid level in each individual chamber (compartment) of the container can be adjusted to the same height (the same level), and at the same time, a uniform dielectric layer or a uniform semiconductor layer can be stably formed on a plurality of conductive members while maintaining a constant forming range.

The present invention provides the following means to achieve the aforementioned objects.

Means for Solving the Problems

[1] A reaction container for manufacturing a capacitor element, comprising:

a container configured to accommodate electrolytic solution therein;

a partitioning frame configured to partition an inside of the container into a plurality of individual chambers;

cathode members individually disposed in each of the individual chambers; and

a passage provided in an openable and closable manner to allow movement of the electrolytic solution between one of the individual chambers and at least adjacent one of the individual chambers adjacent to the one of the individual chambers.

[2] The reaction container for manufacturing a capacitor element as recited in the aforementioned Item 1, wherein

the partitioning frame includes a lower partitioning frame formed on a bottom surface of the container in an upwardly protruded manner and an upper partitioning frame configured to come into contact with an upper surface of the lower partitioning frame in a liquid-tight manner,

the upper partitioning frame is configured to move in an up-and-down direction,

the inside of the container is partitioned into a plurality of individual chambers by arranging the upper partitioning frame on the upper surface of the lower partitioning frame, and

the passage is formed between the two partitioning frames by detaching the upper partitioning frame from the lower partitioning frame.

[3] The reaction container for manufacturing a capacitor element as recited in the aforementioned Item 2, wherein

a first contact plate portion is provided on an upper end of a partition wall of the lower partitioning frame, wherein an upper surface of the first contact plate portion is formed into a smooth surface and a width of the upper surface of the first contact plate portion is set to be larger than a thickness of the partition wall of the lower partitioning frame,

a second contact plate portion is provided on a lower end of a partition wall of the upper partitioning frame, wherein a lower surface of the second contact plate portion is formed into a smooth surface and a width of the lower surface of the second plate contact portion is set to be larger than a thickness of the partition wall of the upper partitioning frame, and

the inside of the container is partitioned into a plurality of individual chambers by arranging the upper partitioning frame on the upper surface of the lower partitioning frame in such a manner that the lower surface of the second contact plate portion of the upper partitioning frame is in contact with the upper surface of the first contact plate portion of the lower partitioning frame.

[4] The reaction container for manufacturing a capacitor element as recited in any one of the aforementioned Items 1 to 3, wherein a liquid passing space is provided inside a structural wall of the container.

[5] The reaction container for manufacturing a capacitor element as recited in any one of the aforementioned Items 1 to 4, further comprising a circuit board having a power supply capable of limiting voltage and electric current and electrically connected to the cathode member.

[6] The reaction container for manufacturing a capacitor element as recited in the aforementioned Item 5, wherein the circuit board is arranged at a bottom surface side of the container.

[7] The reaction container for manufacturing a capacitor element as recited in the aforementioned Items 5 or 6, wherein a component constituting the power supply is thermally connected to the container.

[8] The reaction container for manufacturing a capacitor element as recited in any one of the aforementioned Items 1 to 7, wherein the reaction container is used to form a dielectric layer on a surface of each of a plurality of conductive members by anodization by individually immersing each of the plurality of conductive members into chemical conversion treatment solution in each individual chamber.

[9] The reaction container for manufacturing a capacitor element as recited in any one of the aforeed Items 1 to 8, wherein the reaction container is used to form a semiconductor layer on a surface of a dielectric layer formed on a surface of each of the plurality of conductive members by individually immersing each of the plurality of conductive members in semiconductor layer forming solution in each individual chamber of the container.

[10] A method for manufacturing a capacitor element using the reaction container for manufacturing a capacitor element as recited in any one of the aforementioned Items 1 to 7, the method comprises:

a dielectric layer forming step for forming a dielectric layer on a surface of a conductive member by individually immersing the conductive member into chemical conversion treatment solution in each individual chamber of the reaction container for manufacturing a capacitor element, and in a state in which the passage is closed, passing electric current between the conductive member as an anode and the cathode member of the reaction container as a cathode; and

a liquid level adjusting step for adjusting a liquid level of the chemical conversion treatment solution by opening the passage of the reaction container.

[11] A method for manufacturing a capacitor element using the reaction container for manufacturing a capacitor element as recited in any one of the aforementioned Items 1 to 7, the method comprises:

a semiconductor layer forming step for forming a semiconductor layer on a surface of a dielectric layer of the conductive member by individually immersing the conductive member having the dielectric layer on the surface thereof into the semiconductor layer forming solution in each individual chamber of the reaction container for manufacturing a capacitor element, and in a state in which the passage is closed, passing electric current between the conductive member as an anode and the cathode member of the reaction container as a cathode; and

a liquid level adjusting step for adjusting a liquid level of the semiconductor layer forming solution by opening the passage of the reaction container.

[12] A method for manufacturing a capacitor element using the reaction container for manufacturing a capacitor element as recited in any one of the aforementioned Items 1 to 7, the method comprises:

a dielectric layer forming step for forming a dielectric layer on a surface of a conductive member by individually immersing the conductive member into chemical conversion treatment solution in each individual chamber of the reaction container for manufacturing a capacitor element, and in a state in which the passage is closed, passing electric current between the conductive member as an anode and the cathode member of the reaction container as a cathode;

a liquid level adjusting step for adjusting a liquid level of the chemical conversion treatment solution by opening the passage of the reaction container;

a semiconductor forming step for forming a semiconductor layer on a surface of a dielectric layer of the conductive member by individually immersing the conductive member having the dielectric layer on the surface thereof obtained by the dielectric layer forming step in the semiconductor layer forming solution in each individual chamber of the reaction container for manufacturing a capacitor element, and in a state in which the passage is closed, passing electric current between the conductive member as an anode and the cathode member of the reaction container as a cathode; and

a liquid level adjusting step for adjusting a liquid level of the semiconductor layer forming solution by opening the passage of the reaction container.

[13] The method for manufacturing a capacitor element as recited in any one of the aforementioned Items 10 to 12, wherein the liquid level adjusting step is performed in a non-electric current passing state.

[14] A method of manufacturing a capacitor, comprising:

electrically connecting electrode terminals to the conductive member and the semiconductor layer of the capacitor element obtained by the method as recited in any one of the aforementioned Items 10 to 13, respectively; and

sealing the capacitor element except for a part of the electrode terminals.

Effects of the Invention

According to the invention as recited in the aforementioned item [1], since cathode members are respectively disposed in (connected to) each individual chamber of the reaction container, electrolytic reaction, such as, e.g., anodization or electrolytic polymerization, can be conducted in a state in which each conductive member (anode member) disposed in each individual chamber (compartment) is precisely controlled to a predetermined constant current value, and a uniform dielectric layer and a uniform semiconductor layer can be formed with respect to a plurality of conductive members (anode members). Also, since a passage that allows the movement of electrolytic solution between one of individual chambers and at least adjacent one of the individual chambers adjacent to the one of individual chamber is provided, the height of the liquid level in each individual chamber (compartment) can be adjusted to the same height (the same level) by opening the passage to keep the forming range of the dielectric layer and the semiconductor layers constant, and uniformity (for example, uniformity of concentration) of the electrolytic solution in each compartment can also be adjusted by opening the passage, uniform capacitor elements can be manufactured.

According to the invention as recited in the aforementioned item [2], since the partitioning frame includes a lower partitioning frame formed on a bottom surface of the container in an upwardly protruded manner and an upper partitioning frame configured to come in contact with an upper surface of the lower partitioning frame in a liquid-tight manner, and the upper partitioning frame can be moved in an up-and-down direction, which allows the inside of the container to be partitioned into a plurality of individual chambers by arranging the upper partition frame on the upper surface of the lower partitioning frame to close the passage, electrolytic reaction, such as, e.g., anodization or electrolytic polymerization, can be conducted in a state in which each conductive member (anode member) disposed on each individual chamber (compartment) is precisely controlled to a predetermined constant current value.

On the other hand, the passage can be formed (passage can be opened) between the two partitioning frames by detaching the upper partitioning frame from the lower partitioning frame. Such opening of the passage enables adjustment of the liquid level of each chamber (compartment) to the same height (the same level) and adjustment of uniformity (for example, uniformity of density) of electrolytic solution in each chamber.

Also, since the lower partitioning frame is joined to the bottom surface of the container, the container can be further strengthened (reinforced).

According to the invention as recited in the aforementioned item [3], since a large area of the upper surface (the contact surface) of the first contact plate portion provided at the upper end of a partition wall of the lower partitioning frame and a large area of the bottom surface of the second contact plate portion provided at the lower end of a partition wall of the upper partitioning frame can be secured, the contact area of the two contact surfaces becomes larger, and therefore sufficient liquid-tight state can be secured when arranging the upper partitioning frame on the upper surface of the lower partitioning frame.

According to the invention as recited in the aforementioned item [4], since a liquid passing space is provided inside a structural wall of the container, the temperature of the electrolytic solution (chemical conversion treatment solution, semiconductor layer forming solution, etc.) inside the container can be controlled very accurately by passing liquid, such as, e.g., water, at a constant temperature through the liquid passing space.

According to the invention as recited in the aforementioned item [5], since the reaction container for manufacturing a capacitor element further includes a circuit board having a power supply capable of limiting voltage and electric current and electrically connected to the cathode member, there is an advantage that the conductive member (anode member) only needs to be connected to a simple metal plate (a metal elongated plate, etc.) not having an electric circuit (a simple metal plate not having an electric circuit can be used as a capacitor element manufacturing jig).

According to the invention as recited in the aforementioned item [6], since the circuit board is arranged at a bottom surface side of the container, the reaction container device can be made more compact and the container can be strengthened, especially the bottom surface of the container can be strengthened (reinforced).

According to the invention as recited in the aforementioned item [7], since a component (especially semiconductor component) constituting the power supply is thermally connected to the container in which the temperature is controlled, the temperature of the components constituting these power supplies can be controlled to some degree and the operational state of the power supply can be stabilized, and a more uniform dielectric layer and semiconductor layer can be formed.

According to the invention as recited in the aforementioned item [8], a reaction container that can form a dielectric layer that is uniform with respect to a plurality of conductive members (anode members) is provided.

According to the invention as recited in the aforementioned item [9], a reaction container capable of forming a uniform semiconductor layer with respect to a plurality of conductive members (anode members) in which dielectric layers are formed on the surface thereof, is provided.

According to the invention as recited in the aforementioned item [10], since anodizing reaction can be conducted in a state in which each conductive member (anode member) disposed in each individual chamber (compartment) of the reaction container is accurately controlled to a predetermined constant current value, and a uniform dielectric layer with respect the plurality of conductive members (anode members) can be formed, and since the forming range of the dielectric layer of each conductive member (anode member) can be maintained constant by adjusting the liquid level of each individual chamber (compartment) to the same height by opening the passage of the partitioning member, a number of uniform capacitor elements can be manufactured.

According to the invention as recited in the aforementioned item [11], electrolytic polymerization can be conducted in a state in which each conductive member (anode member) disposed in each individual chamber (compartment) of the reaction container is accurately controlled to a predetermined constant current value, and a uniform semiconductor layer with respect the plurality of conductive members (anode members) can be formed, and since the forming range of the semiconductor layer of each conductive member (anode member) can be maintained constant by adjusting the liquid level of each individual chamber (compartment) to the same height by opening the passage of the partitioning member, a number of uniform capacitor elements can be manufactured.

According to the invention as recited in the aforementioned item [12], anodizing and electrolytic polymerization can be conducted in a state in which each conductive member (anode member) disposed in each individual chamber (compartment) of the reaction container is accurately controlled to a predetermined constant current value, and a uniform dielectric layer and a uniform semiconductor layer with respect the plurality of conductive members (anode member) can be formed, and since the forming range of the dielectric layer and semiconductor layer of each conductive member (anode member) can be maintained constant by adjusting the liquid level of each individual chamber (compartment) to the same height by opening the passage of the partitioning member, a number of uniform capacitor elements can be manufactured.

According to the invention as recited in the aforementioned item [13], since the aforementioned liquid level adjusting step is performed in a non-electric current passing state, a number of uniform capacitor elements can be manufactured.

According to the invention as recited in the aforementioned item [14], a number of high quality capacitors having a uniform function can be manufactured.

EMBODIMENTS FOR CARRYING OUT THE INVENTION

One embodiment of a reaction container1for manufacturing a capacitor element according to the present invention is shown inFIGS. 1 to 3. The reaction container1for manufacturing a capacitor element is provided with a container2, a partitioning frame3, cathode members6, and a voltage and current controllable power source7.

The container2is a container or a case capable of accommodating electrolytic solution (chemical conversion treatment liquid, semiconductor layer forming solution, etc.) therein. In this embodiment, the container2is formed into an approximately rectangular parallelepiped shape with the upper end opened and is formed by insulation material such as resin (acrylic resin, etc.) (seeFIG. 1).

The container2has a jacket structure. That is, as shown inFIG. 3, the container2is provided with a liquid passing space21communicating the inside of the four side walls and the inside of the bottom wall. By passing a temperature controlled liquid (e.g., heated water) through the liquid passing space21, the temperature of the electrolytic solution (chemical conversion treatment liquid, semiconductor layer forming solution, etc.) accommodated in the container2can be controlled with a high degree of accuracy.

The partitioning frame3includes a lower partitioning frame4protruded upward from the bottom wall of the container2and an upper partitioning frame5capable of coming into contact with the upper surface of the lower partitioning frame4in a liquid-tight manner (seeFIG. 3). The lower partitioning frame4and the upper partitioning frame5are each formed by insulating material such as resin (acrylic resin, etc.). The upper partitioning frame5is movable in the up-and-down direction by a driving means (not illustrated). The lower partitioning frame4and the bottom wall of the container2are secured in a liquid-tight manner to prevent possible leakage of the electrolytic solution19therebetween.

The lower partitioning frame4is constituted by longitudinal partition walls11and transverse partition walls11connected in an orthogonally-crossed manner to form a plurality of individual chambers9in an approximate grid-shaped manner in a plane view (seeFIGS. 1 to 3). At the upper end of the partition wall11of the lower partitioning frame4, a first contact plate portion12is provided (seeFIG. 3). The upper surface of the first contact plate portion12is formed into a smooth surface. The width W1of the upper surface of the first contact plate portion12is larger than the thickness T1of the partition wall11of the lower partitioning frame4(seeFIG. 3).

The upper partitioning frame5is constituted by longitudinal partition walls13and transverse partition walls13connected in an orthogonally-crossed manner to form a plurality of individual chambers9in an approximate grid manner in a plane view (seeFIGS. 1 to 3). The number, the size in a plane view, and the arrangement of the individual chambers9of the upper partitioning frame5are the same as the number, the size in a plane view, and the arrangement of the individual chambers9of the lower partitioning frame4(seeFIGS. 1 to 3). At the lower end of the partition wall13, a second contact plate portion14is provided (seeFIG. 3). The lower surface of the second contact plate portion14is formed into a smooth surface. The width W2of the lower surface of the second contact plate portion13is larger than the thickness T2of the partition wall13of the upper partitioning frame5(seeFIG. 3).

In this embodiment, the plurality of individual chambers9are arranged in a grid-shaped manner, but the arrangement is not limited to it. For example, a honeycomb arrangement can be employed.

By arranging the upper partitioning frame5on the upper surface of the lower partitioning frame4in a state in which the lower surface of the second contact plate portion14of the upper partitioning frame5is in contact with the upper surface of the first contact plate portion12of the lower partitioning frame4, the inner space of the container2can be partitioned into a plurality of individual chambers9in a liquid-tight manner (in such a manner that no liquid leakage occurs between the individual chambers) (seeFIG. 6). On the other hand, from such a stacked state, by moving the upper partitioning frame5upward to detach the upper partitioning frame5from the lower partitioning frame4toward the upper side, a passage8can be formed between the lower partitioning frame4and the upper partitioning frame5(between the first contact plate portion12and the second contact plate portion14) (seeFIG. 3). As explained above, in this embodiment, the partitioning frame3includes the lower partitioning frame4protruded form the bottom surface of the container2and the upper partitioning frame5capable of coming into contact with the upper surface of the lower partitioning frame4, and the upper partitioning frame5is movable in the up-and-down direction. Thus, the reaction container is provided with an openable and closable passage8which enables movable of the electrolytic solution between the plurality of individual chambers9when the passage is opened, and also enable to partition the plurality of individual chambers9in the container2in a liquid-tight manner when the passage is closed. In other words, by arranging the upper partitioning frame5on the upper surface of the lower partitioning frame4, the passage8is closed (seeFIG. 6), while by detaching the upper partitioning frame5upward from the lower partitioning frame4, the passage8is opened (seeFIG. 3). When the passage8is opened, the electrolytic solution can move between one of the individual chambers and all adjacent individual chambers.

The upper and lower pair of walls forming the liquid passing space21in the bottom wall of the container2are provided with through-holes36round in a plane view at corresponding positions in the up-and-down direction (seeFIG. 3). A cylindrical pipe31is inserted from the through-hole36of the upper wall to the through-hole36of the lower wall in a fitted manner. To prevent possible leakage of temperature adjusting liquid flowing in the liquid passing space21, the gaps between the inner peripheral walls of the through-holes and the outer peripheral walls of the end portions of the pipe31are sealed by sealing resin32, such as, e.g., silicone resin (seeFIG. 3).

A circuit board22is arranged at the bottom side of the container2. In detail, the circuit board22is fixed to the lower surface of the bottom wall of the container2via spacers35(seeFIG. 3).

On the upper surface of the circuit board22, as shown inFIG. 4, en electric circuit having a pair of electric connection terminals25and26is formed. One of the electric connection terminals25is provided at one end portion of the circuit board22, while the other electric connection terminal26is provided at the other end portion of the circuit board22. One of the electric connection terminals is a current limiting terminal, and the other is a voltage limiting terminal26.

As the circuit board22, an insulating board is used. The material of the insulating board is not specifically limited, and can be, for example, glass epoxy resin, imide resin, and ceramic. The electric circuit is formed by, for example, copper foils.

The circuit board22is provided with resistors23and transistors24on the upper surface of the circuit board (seeFIGS. 3 and 4). As shown in the electric diagram shown inFIG. 7, one end of the resistor23is connected to the current limiting terminal25, and the emitter of the transistor24is connected to the other end of the resistor23. The cathode member6is connected to the collector of the transistor24, and the base of the transistor24is connected to the voltage limiting terminal26. The cathode member6is connected to the voltage and current controllable power source7as shown inFIGS. 4 and 7. In the present invention, the power source7capable of controlling the voltage and the current of the circuit board22is preferably constituted by a constant current source as shown inFIG. 7, but not limited to it.

The circuit board22includes a plurality of through-holes27penetrating in the up-and-down direction (seeFIG. 3) These through-holes27are provided in the same arrangement as the through-holes36of the bottom wall of the container2(the intervals in the longitudinal direction are the same, and the intervals in the transverse direction are the same).

As shown inFIG. 3, the shaft portion6B of the cathode member6made of a bolt is inserted into the through-holes36of the bottom walls of the container2from the above and further inserted into the through-hole27of the circuit board22, and a first nut33is screwed and tightened to the tip end portion of the bolt shaft6B downwardly protruded from the through-hole27of the circuit board22. Thus, the circuit board22is fixed to the bottom surface side of the container2, and the head portion6A of the bolt is protruded from the bottom surface in each individual chamber9and constituted as the cathode member6(seeFIGS. 3 and 5). As explained above, in each individual chamber9, the cathode members6are arranged individually (FIGS. 2 and 3). A second nut34is screwed to the shaft portion6B of the cathode member6between the bottom wall of the container2and the circuit board22in such a manner that the nut electrically contacts the electric circuit on the upper surface of the circuit board22. In other words, the cathode member6electrically contacts the electrical circuit on the upper surface of the circuit board22via the second nut34(seeFIG. 4).

Next, a method of manufacturing a capacitor element using the aforementioned capacitor element manufacturing reaction container1will be explained. InFIG. 6, one example of the manufacturing method of a capacitor element according to the present invention is shown.

As shown inFIG. 3, a member in which the basal end of the lead wire53is connected to the conductive member (anode member)52and the tip end of the lead wire53is connected to one widthwise end portion (i.e., the lower end portion) of an elongated metal plate (capacitor element manufacturing jig)58is provided.

Electrolytic solution19is poured in the container2of the capacitor element manufacturing reaction container1in which the upper partitioning frame5is detached from the lower partitioning frame4as shown inFIG. 3. As the electrolytic solution19, chemical conversion treatment solution for forming a dielectric layer54and semiconductor layer forming solution or the like for forming a semiconductor layer55can be exemplified.

Next, the upper partitioning frame5is moved downward so that the lower surface of the second contact plate portion14of the upper partitioning frame5is brought into contact with the upper surface of the first contact plate portion12of the lower partitioning frame4protruded upward from the bottom surface of the container2to arrange the upper partitioning frame5on the lower partitioning frame4(that is, so that the passage8is brought into the closed state), to thereby partition the inner space of the container2into a plurality of individual chambers9(seeFIG. 6). At this time, it is preferable to adjust the amount of the electrolytic solution19so that the liquid level of the electrolytic solution19is positioned above the upper surface of the lower partitioning frame4but lower the upper surface of the upper partitioning frame5(seeFIG. 6). With this partitioning, it becomes possible to secure the liquid-tight state in which no movement of the electrolytic solution is allowed between the adjacent individual chambers9.

Next, the elongated metal plate58(capacitor element manufacturing jig) to which the conductive members52(anode members) are set is arranged at a position above the container2of the capacitor element manufacturing reaction container1. From this state, the elongated metal plate58is lowered until at least apart of (normally, the entirety of) the conductive member52(anode member) is immersed in the electrolytic solution19and fixed the elongated metal plate58at the height position (seeFIG. 6).

At this time, it is preferable that, in a state in which a plurality of elongated metal plates58each having the anode members52are arranged in parallel, the plurality of elongated metal plates58are suspended from and fixed to an elongated holding frame (not illustrated) made of metal such as stainless steel and the elongated holding frame is lowered to thereby lower the elongated metal plates58. Each anode member52is electrically connected to the elongated holding frame via the lead wire53and the elongated metal plate58.

Next, in the immersed state of the conductive members (anode members)52, electric current is passed between the conductive member52as an anode and each cathode member6arranged in the electrolytic solution19in each individual chamber9. By using chemical conversion treatment solution as first electrolytic solution19, a dielectric layer54(seeFIG. 8) can be formed on the surface of the conductive member52by applying current (dielectric layer forming step).

The maximum value of the voltage to be applied to the anodic member (conductive member)52can be set by the voltage applied between the elongated plate holding frame and the voltage limiting terminal26. The maximum value of the current to be applied to the anode member (conductive member)52can be set by the voltage applied between the voltage limiting terminal26and the current limiting terminal25.

During the dielectric layer forming step, the passage8of the capacitor element manufacturing reaction container1is opened once or plural times periodically, or irregularly. In other words, the upper partitioning frame5is moved upward to detach the upper partitioning frame5from the lower partitioning frame4to thereby form the passage8between the partitioning frames4and5(i.e., the closed passage8is opened). With this, the chemical conversion treatment solution19can be moved between the adjacent individual chambers9. As a result, the liquid levels of the chemical conversion treatment solution19in the individual chambers (compartments)9can be adjusted to the same height (the same level) (seeFIG. 3). Thus, the forming region of the dielectric layer54in each conductive member52can be kept constant (First liquid level adjusting step). The first liquid level adjusting step can be performed periodically or irregularly each after repeating the dielectric layer forming step one to plural times.

Next, the chemical conversion treatment solution19is removed from the container2. The conductive members (anode members)52each having the dielectric layer54are taken out from the container, water washed, and dried, depending on the needs. Thereafter, semiconductor layer forming solution19is newly introduced into the container2.

Next, the upper partitioning frame5is lowered to arrange the upper partitioning frame5on the lower partitioning frame4so that the lower surface of the second contact plate portion14of the upper partitioning frame5is brought into contact with the upper surface of the first contact plate portion12of the lower partitioning frame4protruded upward from the bottom surface of the container2(i.e., the passage8is closed), to thereby partition the inside of the container2into a plurality of individual chambers9(seeFIG. 6). At this time, it is preferable to adjust the amount of the semiconductor layer forming solution such that the liquid level of the semiconductor layer forming solution19takes a position above the upper surface of the lower partitioning frame4and below the upper surface of the upper partitioning frame5(seeFIG. 6). With such partitioning, it becomes possible to secure the liquid-tight state in which the semiconductor layer forming solution19cannot move between the adjacent individual chambers9.

Next, the elongated metal plate58to which conductive members (anode members)52each having the dielectric layer54formed on the surface thereof is arranged at the position above the container2of the semiconductor element manufacturing reaction container1and then lowered until at least a part of (normally, the entirety of) the conductive member (anode member)52is immersed in the semiconductor layer forming solution19, and then the elongated metal plate58is fixed at the height position (seeFIG. 6).

Next, in the immersed state of the conductive member (anode member)52, by passing electric current between the conductive member52as an anode and each cathode member6arranged in the semiconductor layer forming solution19in each individual chamber9as a cathode, i.e., energizing using the semiconductor layer forming solution as second treatment solution19, a semiconductor layer55can be laminated on the surface of the dielectric layer54formed on the surface of the conductive member52(semiconductor layer forming step). Thus, a capacitor element56in which a dielectric layer54is formed on the surface of the conductive member52and a semiconductor layer55is laminated on the surface of the dielectric layer54can be manufactured (seeFIG. 8).

During the semiconductor layer forming step, the passage8of the capacitor element manufacturing reaction compartment1is opened once or plural times periodically, or irregularly. In other words, the upper partitioning frame5is moved upward to detach the upper partitioning frame5from the lower partitioning frame4to thereby form the passage8between the partitioning frames4and5(i.e., the closed passage8is opened). With this, the semiconductor layer forming solution19can be moved between the adjacent individual chambers9. As a result, the liquid levels of the chemical conversion treatment solution19in the individual chambers (compartments)9can be adjusted to the same height (the same level) (seeFIG. 3). Thus, the forming region of the semiconductor layer55can be kept constant (Second liquid level adjusting step). The second liquid level adjusting step can be performed periodically or irregularly each after repeating the semiconductor layer forming step one to plural times.

According to the manufacturing method of a capacitor element of the present invention, in a state in which the current passing each conductive member (anode member)52arranged in each individual chamber (compartment) of the reaction container can be precisely controlled to a predetermined constant current value. This enables uniform formation of the dielectric layer54and semiconductor layer55to the plurality of conductive members (anode members)52. Further, by opening the passage8of the partitioning frame3, the liquid level in each individual chamber (compartment)9can be adjusted to the same height (the same level) to maintain a constant forming range of the dielectric layer and semiconductor layer on each conductive member (anode member)52, which enables to manufacture a number of uniform capacitor elements56.

In the aforementioned embodiment, the up-and-down movement of the upper partitioning frame5and the up-and-down movement of the elongated metal plate (capacitor element manufacturing jig)58to which the conductive members52are attached are performed separately, but not limited to it. For example, it can be configured such that the upper partitioning frame5and the elongated metal plate (capacitor element manufacturing jig)58are integrally formed and that the upper partitioning frame5and the elongated metal plate58are simultaneously moved in the up-and-down direction with a single elevating means. In this case, there is a merit that the number of elevating means can be one. Alternatively, at the time of immersing the conductive members52connected to the elongated metal plate58in the electrolytic solution, it can be configured such that the upper partitioning frame5in which a part thereof is positioned below the liquid level is lowered with an elevating means.

In the aforementioned embodiment, it is constituted that the partitioning frame3includes a lower partitioning frame4secured to the bottom wall of the container2and the upper partitioning frame5, but the partitioning frame3is not limited to it. For example, it can be constituted such that the lower partitioning frame4is omitted. In this case, in order to secure the liquid-tight state which causes no liquid leakage when the lower surface of the upper partitioning frame5which is movable in the up-and-down direction is in contact with the upper surface of the bottom wall of the container2, the lower surface of the upper partitioning frame5and the upper surface of the bottom wall of the container2are each formed into a smooth surface. In cases where the partitioning frame3is constituted only by the upper partitioning frame5movable in the up-and-down direction, there is a merit that the liquid such as the electrolytic solution can be easily discharged.

The conductive member52is not specifically limited. For example, at least one of conductive members selected from the group consisting of valve action metal and conductive oxide of the valve action metal can be exemplified. The concrete examples thereof include aluminum, tantalum, niobium, titan, zirconium, niobium monoxide, and zirconium monoxide.

The shape of the conductive member52is not specifically limited, and can be, for example, a foil-like shape, a plate-like shape, a bar-like shape, and a rectangular parallelepiped shape.

The chemical conversion treatment solution19is not specifically limited, and can be, for example, solution in which conventionally known electrolytic solution, such as, e.g., organic acid or its salt (for example, adipic acid, acetic acid, ammonium adipate, benzoic acid), inorganic acid or its salt (for example, phosphoric acid, silicic acid, ammonium phosphate, ammonium silicate, sulfuric acid, and ammonium sulfate) is dissolved or suspended. By energizing using such chemical conversion treatment solution, a dielectric layer54containing insulating metallic oxide, such as, e.g., Ta2O5, Al2O3, Zr2O3, or Nb2O5, can be formed on the surface of the conductive member52.

It can be configured such that the conductive member52having the dielectric layer54formed on the surface thereof is subjected to the semiconductor layer forming step by omitting the dielectric layer forming step using such chemical conversion treatment solution. The dielectric layer54on the surface can be, for example, a dielectric layer having at least one element as a main component selected from insulating oxides, or a dielectric layer known in the field of ceramic capacitors or film capacitors.

The semiconductor layer forming solution19is not specifically limited as long as it is solution capable of forming a semiconductor layer by energization, and can be, for example, solution containing aniline, thiophene, pyrrole, methylpyrrole and its substituted derivative thereof (for example, 3,4-ethylenedioxythiophene). Dopant can be further added to the semiconductor layer forming solution19. The dopant is not specifically limited, and can be any known dopant, such as, e.g., arylsulfonic acid or its salt, alkyl sulfonic acid or its salt, or various polymer sulfonic acid. By energizing using such semiconductor layer forming solution19, a semiconductor layer55made of, for example, conducting polymer (for example, polyaniline, polythiophene, polypyrrole, polymethylpyrrole) can be formed on the surface of the dielectric layer54formed on the surface of the conductive member52.

In the present invention, an electrode layer can be formed on the semiconductor layer55of the capacitor element56obtained by the aforementioned manufacturing method to enhance the electric contact to a pullout lead (for example, a lead frame) of a capacitor.

The electrode layer can be formed by, for example, solidification of conductive paste, plating, metal evaporation, or formation of a heat-resistance conductive resin film. The conductive paste is preferably silver paste, copper paste, aluminum paste, carbon paste, nickel paste, or the like. The paste can be one of them or two or more of them. In the case of using two or more conductive pastes, they can be mixed, or can be laminated to form separate layers.

Electric terminals are electrically connected to the conductive member52and the semiconductor layer55of the capacitor element56obtained as mentioned above (for example, a lead wire53is welded to one of electric terminals, and the electrode layer (semiconductor layer)55is welded to the other electric terminal), and sealed except for a part of the electric terminal. Thus, a capacitor is obtained.

The sealing method is not specifically limited, and can be, for example, resin mold covering, resin case covering, metal case covering, resin dipping covering, or laminate film covering. Among them, resin mold covering is preferable since the miniaturization and cost reduction can be easily performed.

EXAMPLES

Next, concrete examples of the present invention will be explained, but it should be noted that the present invention is not limited to one of them.

Production of Anode Member (Conductive Member)52

Niobium power having an average particle diameter of 125 μm was obtained by granulating niobium primary powder (average grain diameter of 0.17 μm) obtained by pulverizing a niobium (Nb) ingot using the hydrogen brittleness. Next, the obtained niobium powder was partially nitrided to obtain partially nitrided niobium powder (oxygen content: 6,500 mass ppm, nitrogen content: 7,600 ppm, CV value: 280,000 μF·V/g). The partially nitrided niobium powder was molded together with a niobium wire (lead wire) having a diameter of 0.29 mm, and then vacuum sintered at 1,240° C. to obtain a sintered body (anode member)52of a rectangular parallelepiped shape having a length of 2.3 mm, a width of 1.7 mm, a thickness of 1.0 mm, and a mass of 15.2 mg. The niobium lead wire53was buried approximately in the center of the surface of 1.7 mm×1.0 mm, and integrally formed with the sintered body52such that the lead wire53was outwardly extended from the surface by 10 mm. A washer of tetrafluoroethylene having an inner diameter of 0.26 mmφ), an outer diameter of 0.80 mmφ, a thickness of 0.20 mm was attached to the lead wire53of the anode member52away from the lead wire53mounting surface by 0.15 mm.

[Production of Elongated Metal Plate58Equipped with Anode Members52]

As shown inFIGS. 1 and 3, an elongated metal plate (capacitor element manufacturing jig) equipped with anode members52was manufactured. Initially, the tip end portion of the lead wire53of the anode member (conductive member)52was connected by welding to the lower end portion of the stainless steel elongated metal plate58having a length (horizontal length) of 200 mm, a width (vertical length) of 30 mm, and a thickness of 2 mm. A total of 32 pieces of anode members52were connected at the intervals of 5 mm between adjacent lead wires53(figures are simplified by reducing the number of anode members). Next, a total of 20 pieces of the elongated plate holding frames58having the anode members52were arranged in parallel at an intervals of 8 mm and suspended from and fixed to a stainless steel elongated plate holding frame. With this, the anode members52are electrically connected to the elongated plate holding frame vial the lead wire53and the elongated metal plate58. A total of 640 pieces of anode members52were arranged under the elongated plate holding frame with the arrangement of 32 by 20.

The aforementioned capacitor element manufacturing reaction container1shown inFIGS. 1 to 3was prepared. As the container2, an acrylic resin container of a rectangular parallelepiped shape having a length of 240 mm, a width of 300 mm, and a height of 130 mm was used. The container2was configured such that heated water (heated water for controlling the electrolytic solution) was passed through the liquid passing space21formed in the four side wall and the bottom wall. The container was provided with a total of 640 individual chambers (compartments)9in the arrangement of 32 by 20 formed by the partitioning frame32. The lower partitioning frame4was a grid-shaped frame of acrylic resin, and was 50 mm in height, 2 mm in thickness T1of the partition wall11, 3 mm in width W1of the first contact plate portion12(seeFIG. 3). The upper partitioning frame5was a grid-shaped frame of acrylic resin, and 20 mm in height, 2 mm in thickness T2of the partition wall13, and 3 mm in the width W2of the second contact plate portion14(seeFIG. 3). The cathode member6was a stainless steel bolt having a shaft external diameter of 1 mm and the head outer diameter of 2 mm.

At the bottom surfaced side of the container2, a copper coated glass epoxy board (circuit board)22having approximately the same size as the bottom surface of the container2and a thickness of 1.6 mm was fixedly arranged with stainless bolts (cathode members)6at a distance of 0.8 mm from the lower surface of the container2.

On the upper surface of the circuit board22, as shown inFIGS. 4 and 7, each cathode member (bolt)6was electrically connected to each of a total of 640 current and voltage controlling circuits. The resistors23(20 kΩ±0.5%) and transistors24(2SC6026GR) were in contact with the bottom surface (i.e., the bottom wall through which heated water was passed) of the container2via a thermal conductive resin sheet (not illustrated).

The upper partitioning frame5of the capacitor element manufacturing reaction container1was moved upward to make a gap (passage)8of 0.2 mm between the upper partitioning frame5and the lower partitioning frame4. With this state, chemical conversion treatment solution19of 2 mass % phosphoric acid aqueous solution was poured in the container2to a depth of 60 mm (seeFIG. 3). By adjusting the temperature of heated water passing through the liquid passing space21of the container2, the temperature of the chemical conversion treatment solution19was maintained at 65° C. By lowering the elongated plate holding frame with a elevating means, the anode member52was arranged so that the upper edge (lead wire embedded surface) was positioned at a depth of 5 mm from the liquid level. Next, the upper partitioning frame5was lowered slowly so as not to cause waves to bring the lower surface of the second contact plate portion14of the upper partitioning frame5into contact with the upper surface of the first contact plate portion12of the lower partitioning frame4to thereby close the passage8. Thus, the inside of the container2was partitioned into 640 individual chambers9(seeFIG. 6).

Next, it was set that the maximum voltage applied to the anode member52became 10 V (the voltage controlling terminal was held at a voltage of about −9.2 V with respect to the elongated plate holding frame by a DC power source) and that the maximum current per each anode member52was also set to 2 mA (the current controlling terminal was held at a voltage of about −40.6 V with respect to the voltage controlling terminal by a DC power source29), and chemical conversion treatment was initiated.

Every 15 minutes after the initiation of the chemical conversion treatment, the upper partitioning frame5was raised by 0.5 mm so as not to cause any waves to form a gap8(passage) of 0.5 mm between the upper partitioning frame5and the lower partitioning frame4for about 1 second (i.e., the passage8was opened for about 1 second) (seeFIG. 3). By repeating such liquid level adjusting step every 15 minutes, the liquid level between the individual chambers9(compartments) was adjusted to the same height. Energization was suspended only while the gap8(passage) was formed. Such chemical conversion treatment was performed for 240 minutes to form a dielectric layer54on the surface of the conductive member52.

After completion of the chemical conversion treatment, in the immersed state in the chemical conversion treatment solution, leak current on each anode member52(solution LC value after completion of the chemical conversion treatment) was measured. The amount of leak current was measured with a potential of −10 V applied to the tip end of the shaft portion6B of the cathode member6with respect to the elongated plate holding frame. This measurement of the leak current was performed in a state in which a potential of −10 V with respect to the elongated plate holding frame was applied to both the voltage limiting terminal26and current limiting terminal25. The results of the measurements revealed that the solution LC values after completion of the chemical conversion treatment of 640 anode members were within the range of 29 to 33 μA.

Next, after immersing in 20 mass % iron xylene sulfonate aqueous solution, the chemical conversion treated conductive member (anode member)52was dried to eliminate water. After the series of immersion operation and drying operation were repeated 5 times. Then, the conductive member (anode member)52was immersed in 50 mass % ethylenedioxythiophene ethanol and then dried in air to remove ethanol.

Next, the upper partitioning frame5of the capacitor element manufacturing reaction container1was moved upward to obtain a 0.2 mm gap (passage)8between the upper partitioning frame5and the lower partitioning frame4. In this state, mixed aqueous solution (semiconductor layer forming solution)19of a composition including ethylene glycol 25 mass %, anthraquinone sulfonic acid 0.5 mass %, and ethylenedioxy thiophene 0.5 mass % was poured in an empty container2to a depth of 60 mm (seeFIG. 3). By adjusting the temperature of heated water passing through the liquid passing space21of the container2, the temperature of the semiconductor layer forming solution19was maintained at 26° C. By lowering the elongated plate holding frame by an elevating means, the conductive member (anode member)52having a dielectric layer54formed on the surface thereof by the chemical conversion treatment was immersed in the semiconductor layer forming solution19so that the lower surface of the washer mounted on the lead wire53became the same level as the liquid level of the semiconductor layer forming solution19. Next, the upper partitioning frame5was lowered slowly so as not to cause waves to bring the lower surface of the second contact plate portion14of the upper partitioning frame5into contact with the upper surface of the first contact plate portion12of the lower partitioning frame4to thereby close the passage8. Thus, the inside of the container2was partitioned into 640 individual chambers9(seeFIG. 6).

Next, it was set that the maximum voltage applied to the anode member52became 13 V (the voltage controlling terminal was held at a voltage of about −12.3 V with respect to the elongated plate holding frame by a DC power source) and that the maximum current per each anode member52was also set to 100 μA (the current controlling terminal was held at a voltage of about −2.6 V with respect to the current controlling terminal by a DC power source29), and electrolytic polymerization was initiated.

Every 15 minutes after the initiation of the electrolytic polymerization, the upper partitioning frame5was raised by 0.5 mm so as not to cause any waves to form a gap8(passage) of 0.5 mm between the upper partitioning frame5and the lower partitioning frame4for about 1 second (i.e., the passage8was opened for about 1 second) (seeFIG. 3). By repeating such liquid level adjusting step every 15 minutes, the liquid level between the individual chambers9(compartments) was adjusted to the same height. Energization was suspended only while the gap8(passage) was formed. Such electrolytic polymerization was performed for 60 minutes.

Next, the capacitor element56was pulled out of the semiconductor layer forming solution19, and the semiconductor layer forming solution adhered when immersed in ethanol was washed and removed. Thereafter, the capacitor element was dried in air and the ethanol was removed.

A series of operations including immersion in the semiconductor layer forming solution19, electrolytic polymerization, ethanol washing, and drying in air were further repeated three times (a total 4 times). The set value of the maximum current at the time of electrolytic polymerization was 120 μA at the second time, 180 μA at the third time, and 185 μA at the fourth time.

Using the aforementioned capacitor element manufacturing reaction container1, in the same manner as in the aforementioned chemical conversion treatment, chemical reconversion treatment was performed. However, using 3 mass % phosphoric acid aqueous solution as the chemical conversion treatment solution, the maximum voltage applied to the anode member was set to 7 V, and the maximum current per each anode member was set to 1 mA, and the chemical conversion treatment time was set to 15 minutes. Thereafter, the anode member was pulled out of the chemical conversion treatment solution, rinsed in water, and dried.

Carbon paste and silver paste were applied sequentially to the anode member obtained through the chemical reconversion treatment mentioned above and solidified in a laminated matter to thereby obtain a capacitor element56. The capacitor element56was subjected to lead frame attachment, sealing, aging, frame cutting and bending work, and electric measurement. Thus, 640 pieces of chip-shaped solid conductive members having a size of 3.5 mm×2.8 mm×1.8 mm, a rated voltage of 2.5 V, and a capacity of 330 μF were manufactured.

The obtained 640 pieces of solid conductive members fell within the rage of ESR: 14 mΩ to 20 mΩ (average: 17 mΩ), and the leak currents (LC values) 30 seconds after applying 2.5 V were all less than 33 μA (0.04 CV).

Comparative Example 1

A total of 640 pieces of chip-shaped solid electrolytic capacitors were manufactured in the same manner as in Example 1 except that the chemical conversion treatment and the chemical reconversion treatment were performed in a state in which a gap (passage)8of 0.2 mm between the upper partitioning frame5and the lower partitioning frame4(without performing liquid level adjustment by closing the passage8). The solution LC values at the time of completion of the chemical conversion treatment were within the range of 34 to 52 μA. The obtained 640 solid electrolytic capacitors were within the range of 15 mΩ to 21 mΩ in ESR (average: 18 mΩ). With respect to the leak currents (LC values) 30 seconds after applying 2.5 V, 24 pieces of electrolytic capacitors were 183 μA or more but less than 165 μA in LC value (0.1 VA or more but less than 0.2 CV), 581 pieces of electrolytic capacitors were 33 μA or more but less than 82.5 μA in LC value (0.04 CV or more but less than 0.1 CV), and 35 pieces of electrolytic capacitors were less than 33 μA in LC value (less than 0.04 CV).

Comparative Example 2

A total of 640 pieces of chip-shaped solid electrolytic capacitors were manufactured in the same manner as in Example 1 except that the chemical conversion treatment, electrolytic polymerization, and the chemical reconversion treatment were performed in a state in which a gap (passage)8of 0.2 mm between the upper partitioning frame5and the lower partitioning frame4(without performing liquid level adjustment by closing the passage8). The solution LC values at the time of completion of the chemical conversion treatment were within the range of 33 to 49 μA. The obtained 640 solid electrolytic capacitors were within the range of 18 mΩ to 30 mΩ in ESR (average: 24 mΩ). With respect to the leak currents (LC values) 30 seconds after applying 2.5 V, 137 pieces of electrolytic capacitors were 83 μA or more but less than 165 μA in LC value (0.1 VA or more but less than 0.2 CV), 499 pieces of electrolytic capacitors were 33 μA or more but less than 82.5 μA in LC value (0.04 CV or more but less than 0.1 CV), and 4 pieces of electrolytic capacitors were less than 33 μA in LC value (less than 0.04 CV).

This application claims priority to Japanese Patent Application No. 2009-288710 filed on Dec. 21, 2009, and the entire disclosure of which is incorporated herein by reference in its entirety.

INDUSTRIAL APPLICABILITY

The capacitor element manufacturing reaction container according to the present invention can be preferably used as an electrolytic capacitor element manufacturing reaction container, but not specifically limited to such usage. A capacitor element obtained by the capacitor element manufacturing method of the present invention can be used as, for example, personal computers, server computers, cameras, game machines, DVDs, AV devices, digital devices such as, e.g., cellular phones, or electric devices, such as, e.g., various power sources.

DESCRIPTION OF THE REFERENCE NUMERALS

1Capacitor element manufacturing reaction container2container3partitioning frame4lower partitioning frame5upper partitioning frame6cathode member7voltage and current controllable power source8passage9individual chamber11partition wall (of the lower partitioning frame)12first contact plate portion (lower partitioning frame)13partition wall (of the upper partitioning frame)14second contact plate portion (upper partitioning frame)19electrolytic solution (chemical conversion treatment solution, semiconductor layer forming solution, etc.)21liquid passing space22circuit board23resistor24transistor25current limiting terminal26voltage limiting terminal52anode member (conductive member)54dielectric layer55semiconductor layer56capacitor elementT1thickness of the partition wall of the lower partitioning frameT2thickness of the partition wall of the upper partitioning frameW1width of the first contact plate portionW2width of the second contact plate portion