Patent Description:
A commercially available electrolyte capacitor as a rule is made of a porous metal electrode, an oxide layer serving as a dielectric on the metal surface, an electrically conductive material, usually a solid, which is introduced into the porous structure, an outer electrode (contacting), such as e.g. a silver layer, and further electrical contacts and an encapsulation. An electrolyte capacitor which is frequently used is the tantalum electrolytic capacitor, the anode electrode of which is made of the valve metal tantalum, on which a uniform, dielectric layer of tantalum pentoxide has been generated by anodic oxidation (also called "formation"). A liquid or solid electrolyte forms the cathode of the capacitor. Aluminium capacitors in which the anode electrode is made of the valve metal aluminium, on which a uniform, electrically insulating aluminium oxide layer is generated as the dielectric by anodic oxidation, are furthermore frequently employed. Here also, a liquid electrolyte or a solid electrolyte forms the cathode of the capacitor. The aluminium capacitors are usually constructed as wound- or stacked-type capacitors.

π-conjugated polymers are particularly suitable as solid electrolytes in the capacitors described above because of their high electrical conductivity. π-conjugated polymers are also called conductive polymers or synthetic metals. They are increasingly gaining economic importance, since polymers have advantages over metals with respect to processability, weight and targeted adjustment of properties by chemical modification. Examples of known π-conjugated polymers are polypyrroles, polythiophenes, polyanilines, polyacetylenes, polyphenylenes and poly(p-phenylene-vinylenes), a particularly important polythiophene used industrially being poly(<NUM>,<NUM>-ethylenedioxythiophene) (PEDOT), since it has a very high conductivity in its oxidized form.

The solid electrolytes based on conductive polymers can be applied to the oxide layer in various ways. <CIT> describes, for example, the production of a solid electrolyte from <NUM>,<NUM>-ethylenedioxythiophene and the use thereof in electrolytic capacitors. According to the teaching of this publication, <NUM>,<NUM>-ethylenedioxythiophene is polymerized on to the oxide layer in situ. In addition to the in situ polymerization a processes for the production of solid electrolytes in capacitors in which a dispersion comprising the already polymerized thiophene and a polyanion as a counter-ion, for example the PEDOT/PSS-dispersions (PEDOT = Poly(<NUM>,<NUM>-ethylenedioxythiophene; PSS = polystyrene sulfonic acid) known from the prior art, is applied to the oxide layer and the dispersing agent is then removed by evaporation are also known from the prior art. Such a process for the production of solid electrolyte capacitors is disclosed, for example, in <CIT>.

However, PEDOT/PSS-dispersion are characterised by the disadvantage that they comprise a significant amount of PSS as a non-conducting inert material. Furthermore, due to the presence of PSS the size of the PEDOT/PSS-particles in the dispersions is sometimes too large to ensure that the particles also penetrate into the smaller pores of the porous metal electrode. Finally, the maximum solids content of PEDOT/PSS-dispersions is often limited to values of about <NUM> wt. In order to overcome these disadvantages, liquid compositions comprising derivatives of PEDOT have been prepared which are not characterized by the disadvantages of the known PEDOT/PSS-dispersions. Polythiophenes functionalized with sulfonate groups were developed initially. Due to the sulfonate groups, these polythiophenes are self-doped and do not require counter-ions such as PSS. , for example, discloses the preparation of functionalized π-conjugated polymers such as poly(<NUM>-(<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-ylmethoxy)-<NUM>-butane-sulfonic acid) (PEDOT-S) by oxidative polymerization of the corresponding monomer <NUM>-(<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-ylmethoxy)-<NUM>-butanesulfonic acid (EDOT-S). However, the electrical conductivity of conductive layers prepared by the polymer solutions obtained in <CIT> are usually too low to use these polymer solutions for the preparation of, for example, a solid electrolyte layer in a solid electrolyte capacitor.

<NPL>) give an overview of poly(<NUM>,<NUM>-ethylenedioxythiophene) (PEDT) and its derivatives.

<NPL>) disclose that fast switching redox processes in aqueous media can be obtained in poly(<NUM>,<NUM>-ethylenedioxythiophene)-/poly(allylamine hydrochloride).

<NPL>) disclose the electrochemical synthesis of a new <NUM>,<NUM>-ethylenedioxythiophene monomer functionalized by a sulphonate group.

<NPL>) disclose the chemical and electrochemical synthesis of water-soluble poly(<NUM>-(<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-yl-methoxy)-<NUM>-butanesulfonic acid (PEDOT-S).

<NPL>) disclose the synthesis of two sulfonated polythiophene derivatives poly[(<NUM>-thienyl)ethoxybutanesulfonate] [poly(I)] and poly[<NUM>-(<NUM>-sulfinopropyl)-<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin] [poly(II)] by chemical polymerization with FeCl<NUM>.

<NPL>) disclose the chemical polymerization of a <NUM>,<NUM>-ethylenedioxythiophene derivative bearing a sulfonate group (EDOT-S).

<NPL>) disclose the electrochemical and chemical polymerization of a <NUM>,<NUM>-ethylenedioxythiophene derivative bearing a sulfonate group (EDTS).

<CIT> discloses a solution of a polythiophene comprising water or a mixture of water with a water-miscible organic solvent as the dispersing medium, a polythiophene and a polyanion derived from polystyrene sulfonic acid having a molecular weight in the range from <NUM>,<NUM> to <NUM>,<NUM>, the polythiophene having been polymerized in the presence of a polyanion of polystyrene sulfonic acid.

<CIT> discloses a mixture of neutral polythiophenes and an organic compound containing a dihydroxy, polyhydroxy, carboxyl, amide or lactam group that is used in the preparation of a conductive coating.

Further prior art includes <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

It was therefore an object of the present invention to overcome the disadvantages of the prior art in the field of water-soluble π-conjugated polymers.

In particular, it was an object of the present invention to provide compositions comprising a water-soluble or water-dispersible π-conjugated polymer that, compared to the corresponding compositions known from the prior art, are characterized in that the electrical conductivity of a conductive layer that is prepared from these compositions is increased.

A contribution to the solution of at least one of the above objects is provided by the subject matter of the category-forming independent claims, wherein the therefrom dependent subclaims represent preferred embodiments of the present invention, whose subject matter likewise make a contribution to solving at least one object.

A contribution towards solving these objects is made by a process for producing a liquid composition comprising functionalized π-conjugated polythiophenes, the process comprising the steps of.

Surprisingly it has been discovered that liquid composition comprising functionalized π-conjugated polythiophenes (like PEDOT-S) that enable the formation of conductive layers with an increased conductivity can be prepared by oxidative polymerisation of the corresponding monomers pursuant to the process disclosed in <CIT>, provided that the pH of the monomer solution prior to the polymerization reaction is adjusted to a value below <NUM> and that the chlorine content in this monomer solution is kept below <NUM>,<NUM> ppm.

In process step i) of the process according to the present invention a liquid phase is provided that comprises the thiophene monomer a), an oxidizing agent b) and a solvent c).

According to a first embodiment of the process according to the present invention the thiophene monomers a) are those disclosed in <CIT>. According to a preferred embodiment of these thiophene monomers a) X and Y in the general formula (I) are both oxygen (O), wherein it is particularly preferred that.

In this context it is even more preferred that.

The most preferred functionalized π-conjugated polythiophene in connection with the first embodiment of the process according to the present invention is poly(<NUM>-(<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-ylmethoxy)-<NUM>-butanesulfonic acid) (PEDOT-S) and the most preferred thiophene monomers a) is therefore <NUM>-(<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-ylmethoxy)-<NUM>-butanesulfonic acid (EDOT-S). The EDOT-S monomer that is used for the preparation of PEDOT-S, however, may comprise a certain amount of PRODOT-S (<NUM>-(<NUM>, <NUM>-dihydro-<NUM>-thieno [<NUM>,<NUM>-b][<NUM>,<NUM>]dioxepin-<NUM>-yl)-<NUM>-butanesulfonic acid) as it is disclosed in <CIT>. In case of a mixture of EDOT-S and PRODOT-S the amount of PRODOT-S can be up to <NUM> wt. -%, based on the total amount of such a mixture.

According to a second embodiment of the process according to the present invention the thiophene monomers a) are those disclosed in <CIT>. In this context it is therefore preferred that in the general formula (I).

In this context particularly preferred thiophene monomers are those that are explicitly mentioned in paragraph [<NUM>] of <CIT>.

The oxidation reaction that is performed in process step ii) can be catalyzed by a chemical oxidizing agent, by electrochemical oxidation or by a combination of both methods. In case of an electrochemical oxidation an electrode functions als the oxidizing agent b).

Suitable oxidizing agents b) used as chemical oxidizing agents are salts of heavy metals, preferably iron salts, more preferably FeCl<NUM> and iron(III) salts of aromatic and aliphatic sulfonic acids, H<NUM>O<NUM>, K<NUM>Cr<NUM>O<NUM>, salts of a salt of a peroxodisulfate, such as K<NUM>S<NUM>O<NUM>, Na<NUM>S<NUM>O<NUM>, KmnO<NUM>, alkali metal perborates, and alkali metal or ammonium persulfates, or mixtures of these oxidants. Particularly preferred are salts of a heavy metal, salts of a peroxodisulfate or a mixture thereof. Further suitable oxidants are described, for example, in <NPL>. Particularly preferred oxidizing agents b) are salts of a peroxodisulfate, in particular K<NUM>S<NUM>O<NUM>, Na<NUM>S<NUM>O<NUM>, iron salts, in particular iron(III) chloride, or mixtures of salts of a peroxodisulfate and at least one further compound that catalyzes the cleavage of the peroxodisulfate, like mixtures of salts of a peroxodisulfate and iron salts. However, in view of the requirement (α2), according to which the chloride content of the liquid phase provided in process step i) is less than <NUM>,<NUM> ppm, those oxidizing agents b) are preferred that either do not comprise any chloride or that comprise chloride in such a low content that requirement (α2) is still fulfilled. According to an particularly preferred embodiment of the process according to the present invention the oxidizing agent is a mixture of Fe<NUM>(SO<NUM>)<NUM> and Na<NUM>S<NUM>O<NUM>.

Suitable solvents c) that can be used in the process according to the present invention are water, water-miscible solvents, in particular those selected from the group consisting aliphatic alcohols, such as methanol, ethanol, isopropanol and butanol, diacetone alcohols, ethylene glycol and glycerol, aliphatic ketones, such as acetone and methyl ethyl ketone, aliphatic nitrites, such as acetonitrile or a mixture of at least two of these solvents, in particular a mixture of water and a water-miscible solvent. The most preferred solvent, however, is water. In case of <NUM>-(<NUM>,<NUM>-dihydrothieno[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-ylmethoxy)-<NUM>-butanesulfonic acid (EDOT-S) as the thiophene monomer a) the process according to the present invention therefore enables the production of an aqueous PEDOT-S solution.

The concentration of the thiophene monomer a) in the aqueous phase provided in process step i) is preferably in a range from <NUM> to <NUM> wt. -%, preferably in a range from <NUM> to <NUM> wt.

There are different ways of preparing the liquid phase provided in process step i). The thiophene monomer a) can be dissolved or dispersed in the solvent c), followed by the addition of the oxidizing agent(s) b) (which can also be dissolved or dispersed in a solvent separately), or the oxidizing agent(s) b) is/are first dissolved or dispersed in the solvent c), followed by the addition of the thiophene monomer a) (which can also be dissolved or dispersed in a solvent separately). If more than one oxidizing agent is used, like a mixture of Fe<NUM>(SO<NUM>)<NUM> and Na<NUM>S<NUM>O<NUM>, it is furthermore possible to first mix one of these components with the thiophene monomer a) and the solvent c) and to finally add the second oxidizing agent.

Irrespective the way in which the liquid phase is prepared in process step i), it is particularly preferred to reduce the oxygen content in the components that are used to prepare the liquid phase to such an extent that the oxygen content in the liquid phase is below <NUM>,<NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm and most preferably less than <NUM> ppm, in each case based on the total weight of the liquid phase. According to a particularly preferred embodiment of the process according to the present invention the components that are used to prepare the liquid phase are completely free of any oxygen (i. the oxygen content is <NUM> ppm).

The reduction of the oxygen content can, for example, be accomplished by stirring the components used to prepare the liquid phase under a reduced pressure, by using ultra sound or by degasing these components using an inert gas such as N<NUM>, argon, CO<NUM> or a mixture thereof, or by a combination of the above mentioned approaches.

The polymerization reaction in process step ii) is preferably performed at a temperature in the range from -<NUM> to <NUM>, preferably from <NUM> to <NUM> and for a duration of preferably <NUM> to <NUM> hours, more preferably for <NUM> to <NUM> hours.

After the polymerization reaction is completed, the liquid composition comprising the functionalized π-conjugated polymer, preferably the aqueous solution of PEDOT-S, may be further purified, for example by means of filtration, in particular by means of ultrafiltration, and/or by a treatment with ion exchanger, in particular by a treatment with an anion exchanger and a cation exchanger, for the purpose of further purification. It is also possible to add further additives as described below in connection with the process for the production of a capacitor.

The process according to the present invention is now characterized in that.

Adjusting the pH-value to a value below <NUM> as defined in requirement (α1) is - in view of the requirement defined in (α2) -accomplished using an inorganic or organic acid, preferably an organic or inorganic acid that is substantially free of chloride. Suitable organic acids include carboxylic acids such as formic acid, acetic acid, lactic acid, propionic acid, citric acid, malic acid, fumaric acid or mixtures thereof. Suitable inorganic acids are in particular sulfuric acid, sulfonic acid, nitric acid, phosphonic acid, phosphoric acid or mixtures thereof. It is also possible to use a chloride-containing co-acid, such as hydrochloric acid, in combination with one of these organic or inorganic chloride-free acids, as long as these co-acids are used in such a low amount that requirement (α2) is still fulfilled. According to a particularly preferred embodiment of the process according to the present invention sulfuric acid is used for the adjustment of the pH.

Adjusting the chloride content of the liquid phase provided in process step i) to be less than <NUM>,<NUM> ppm as defined in requirement (α2) is preferably accomplished by choosing components a), b) and c), in particular by choosing oxidizing agents b), which are substantially free of chloride. If necessary, the chloride content of the components used to prepare the liquid phase can be additionally reduced by the treatment of these components with anion exchangers.

According to a particularly preferred embodiment of the process according to the present invention it is also advantageous that
(α3) the oxygen content of the liquid phase provided in process step i) is less than <NUM>,<NUM> ppm, preferably less than <NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm, more preferably less than <NUM> ppm and most preferably less than <NUM> ppm, in each case based on the total weight of the liquid phase. According to a particularly preferred embodiment of the process according to the present invention the oxygen content of the liquid phase provided in process step i) is completely free of any oxygen (i. the oxygen content is <NUM> ppm).

There are different approaches of adjusting the oxygen content in the liquid phase that is provided in process step i) and also to maintain this low oxygen content during the polymerization reaction in process step ii).

According to one approach the liquid phase provided in process step i) (or the liquid components that are used to prepare the liquid phase) can be degassed, for example by introducing an inert gas such as N<NUM>, Argon, CO<NUM> or a mixture thereof into the liquid phase provided in process step i) to reduce the initial oxygen content in the liquid phase. Alternatively, the liquid phase provided in process step i) (or the liquid components that are used to prepare the liquid phase) can be subjected to a treatment with a reduced pressure in order to reduce the initial oxygen content, for example by stirring the liquid phase while applying a vacuum, or can be subjected to a treatment with ultra sound or can be subjected to a combination of a treatment with a reduced pressure and a treatment with ultra sound.

In order to ensure that the low oxygen content is maintained during the polymerization reaction in process step ii) it may be advantageous to perform the polymerization reaction under an inert gas atmosphere, preferably under a N<NUM>-atmosphere, under a CO<NUM>-atmosphere, under an argon atmosphere or under an atmosphere of a mixture of at least two of these inert gases, wherein it may also be advantageous that the oxidative polymerization in process step ii) is performed under a pressure that is equal to or above the vapor pressure of the liquid phase during the polymerization reaction in process step ii). Preferably, the oxidative polymerization in process step ii) is performed under a pressure that is at least <NUM> mbar, more preferably at least <NUM> mbar and most preferably at least <NUM> mbar above the vapor pressure of the liquid phase during the polymerization reaction in process step ii). To ensure that the low oxygen content is maintained during the polymerization reaction in process step ii) it is also possible to perform the oxidative polymerization in process step ii) under a reduced pressure, preferably under a pressure of not more than <NUM> bar and most preferably under a pressure of not more than <NUM> bar.

Also disclosed herein is a liquid composition comprising functionalized π-conjugated polythiophenes, preferably by an aqueous PEDOT-S solution, that is obtainable by the process according to the present invention, preferably by a liquid composition comprising functionalized π-conjugated polythiophenes, in particular an aqueous PEDOT-S solution, that has been obtained by the process according to the present invention.

In this context it is particularly preferred that a conductive layer made by the liquid composition has a conductivity of more than <NUM>/cm, preferably more than <NUM>/cm, more preferably more than <NUM>/cm, preferably more than <NUM>/cm, more preferably more than <NUM>/cm, more preferably more than <NUM>/cm, more preferably more than <NUM>/cm, more preferably more than <NUM>/cm and most preferably more than <NUM>/cm.

Also disclosed herein is a process for the production of a capacitor, comprising the process steps:.

In process step I), an electrode body of an electrode material, wherein a dielectric covers one surface of this electrode material at least partly to form an anode body, is first provided.

In principle, the electrode body can be produced by pressing a valve metal powder of high surface area and sintering it to give a usually porous electrode body. An electrical contact wire, preferably of a valve metal, such as e.g. tantalum, is conventionally also pressed into the electrode body here. The electrode body is then coated, for example by electrochemical oxidation, with a dielectric, i.e. an oxide layer. Alternatively, metal foils can also be etched, and coated with a dielectric by electrochemical oxidation in order to obtain an anode foil having a porous region. In a wound capacitor, an anode foil having a porous region, which forms the electrode body, and a cathode foil are separated by separators and wound up.

In the context of the invention, valve metal is to be understood as meaning those metals of which the oxide layers do not render possible current flow equally in both directions. In the case of an anodically applied voltage, the oxide layers of the valve metals block the current flow, while in the case of a cathodically applied voltage large currents occur, which may destroy the oxide layer. The valve metals include Be, Mg, Al, Ge, Si, Sn, Sb, Bi, Ti, Zr, Hf, V, Nb, Ta and W and an alloy or compound of at least one of these metals with other elements. The best known representatives of the valve metals are Al, Ta and Nb. Compounds which have electrical properties comparable to a valve metal are those having metallic conductivity, which can be oxidized and of which the oxide layers have the properties described above. For example, NbO has metallic conductivity, but in general is not regarded as a valve metal. Layers of oxidized NbO have, however, the typical properties of valve metal oxide layers, so that NbO or an alloy or compound of NbO with other elements are typical examples of such compounds which have electrical properties comparable to a valve metal. Electrode materials of tantalum, aluminium and those electrode materials based on niobium or niobium oxide are preferred. Tantalum and aluminium are very particularly preferred as the electrode material.

For production of the electrode body, often with a porous region, the valve metals can be sintered, for example in powder form, to give a usually porous electrode body, or a porous structure is stamped on a metallic body. The latter can be carried out e.g. by etching a foil.

For simplicity, bodies having a porous region are also called porous in the following. Thus, for example, electrode bodies having a porous region are also called porous electrode bodies. On the one hand, the porous bodies can be permeated by a plurality of channels and therefore be sponge-like. This is often the case if tantalum is used for construction of the capacitor. Furthermore, it is possible for only the surface to have pores and for the region following under the surface pores to be solid in construction. Such a situation is often observed if aluminium is used for construction of the capacitor. Preferably, the electrode body is porous.

The often porous electrode bodies produced in this manner are then oxidized, for example, in a suitable electrolyte, such as e.g. phosphoric acid or an aqueous solution of ammonium adipate, by application of a voltage, in order to form the dielectric. The level of this formation voltage depends on the oxide layer thickness to be achieved or the later use voltage of the capacitor. Preferred formation voltages lie in a range of from <NUM> to <NUM>,<NUM> V, particularly preferably in a range of from <NUM> to <NUM> V, very particularly preferably in a range of from <NUM> to <NUM> V. According to a first particular embodiment of the process for the production of a capacitor the formation voltage is in a range of from <NUM> to <NUM> V, whereas according to a second particular embodiment of the process for the production of a capacitor the formation voltage is in a range of from <NUM> to <NUM> V.

The as a rule porous electrode bodies employed preferably have a porosity of from <NUM> to <NUM> %, preferably from <NUM> to <NUM> %, particularly preferably from <NUM> to <NUM> % and an average pore diameter of from <NUM> to <NUM>,<NUM>, preferably from <NUM> to <NUM>,<NUM>, particularly preferably from <NUM> to <NUM>,<NUM>.

According to a particular embodiment of the process for the production of a capacitor, the electrolyte capacitor to be produced is an aluminium wound capacitor. In this case, in process step a) a porous aluminium foil is formed anodically as the electrode material, an aluminium oxide coating being formed as the dielectric. The aluminium foil (anode foil) obtained in this manner is then provided with a contact wire and wound up with a further optionally porous aluminium foil (cathode foil) likewise provided with a contact wire, these two foils being spaced from one another by one or more separators, which are based e.g. on cellulose or, preferably, on synthetic papers. After being wound up, the anode bodies obtained in this way are fixed, for example by means of an adhesive tape. The separator or separators can be carbonized by heating in an oven. This method and manner of production of anode bodies for aluminium wound capacitors is adequately known from the prior art and is described, for example, in <CIT>.

According to further particular embodiments of the process for the production of a capacitor, the electrolyte capacitor to be produced is an aluminium stacked capacitor or a tantalum electrolytic capacitor ("tantalum elco"), in particular a tantalum electrolytic capacitor having a polymeric outer layer, such as is described in <CIT>.

In process step II) of the process for the production of a capacitor, the liquid composition obtainable by the process according to the present invention, preferably an aqueous solution of PEDOT-S, is introduced into at least a part of the anode body. In this context it should be noted that, before introducing the liquid composition obtainable by the process according to the present invention into at least a part of the anode body, other compositions may be introduced into the anode body for the formation of an electrically conductive layer, such as a PEDOT/PSS-dispersion. It is therefore not necessarily required to directly apply the liquid composition obtainable by the process according to the present invention onto at least a part of the dielectric layer of the anode body.

The liquid composition is introduced into the porous region by known processes, e.g. impregnation, dipping, pouring, dripping on, spraying, misting on, knife coating, brushing or printing, for example ink-jet, screen or tampon printing. Preferably, the introduction is carried out by dipping the anode body provided in process step a) into the liquid composition and thus impregnating it with this liquid composition. The dipping into or the impregnation with the liquid composition is preferably carried out for a period in a range of from <NUM> second to <NUM> minutes, particularly preferably in a range of from <NUM> seconds to <NUM> minutes and most preferably in a range of from <NUM> seconds to <NUM> minutes. The introduction of the liquid composition into the anode body can be facilitated, for example, by increased or reduced pressure, vibration, ultrasound or heat.

The liquid composition employed in process step II) can, besides the functionalized π-conjugated polymer a), the solvent c) and optionally a reminder of the oxidizing agent b) in its reduced form, moreover comprise further additives, such as surface-active substances, e.g. anionic surfactants, such as e.g. alkylbenzenesulphonic acids and salts, paraffin sulphonates, alcohol sulphonates, ether sulphonates, sulphosuccinates, phosphate esters, alkyl ether carboxylic acids or carboxylates, cationic surfactants, such as e.g. quaternary alkylammonium salts, nonionic surfactants, such as e.g. linear alcohol ethoxylates, oxo alcohol ethoxylates, alkylphenol ethoxylates or alkyl polyglucosides, in particular surfactants that are commercially available under the trademarks Dynol® and Zonyl®, or adhesion promoters, such as e.g. organofunctional silanes or hydrolysates thereof, e.g. <NUM>-glycidoxypropyltrialkoxysilane, <NUM>-aminopropyl-triethoxysilane, <NUM>-mercaptopropyltrimethoxysilane, <NUM>-methacryloxypropyltrimethoxysilane, vinyltrimethoxysilane or octyltriethoxysilane, crosslinking agents, such as melamine compounds, masked isocyanates, functional silanes - e.g. tetraethoxysilane, alkoxysilane hydrolysates, e.g. based on tetraethoxysilane, epoxysilanes, such as <NUM>-glycidoxypropyltrialkoxysilane - polyurethanes, polyacrylates or polyolefin dispersions.

Preferably, the liquid composition employed in process step II) comprise further additives which optionally increase the conductivity, such as e.g. compounds containing ether groups, such as e.g. tetrahydrofuran, compounds containing lactone groups, such as γ-butyrolactone, γ-valerolactone, compounds containing amide or lactam groups, such as caprolactam, N-methylcaprolactam, N,N-dimethylacetamide, N-methylacetamide, N,N-dimethylformamide (DMF), N-methylformamide, N-methylformanilide, N-methylpyrrolidone (NMP), N-octylpyrrolidone, pyrrolidone, sulphones and sulphoxides, such as e.g. sulpholane (tetramethylene sulphone), dimethylsulphoxide (DMSO), sugars or sugar derivatives, such as e.g. sucrose, glucose, fructose, lactose, sugar alcohols, such as e.g. sorbitol, mannitol, furan derivatives, such as e.g. <NUM>-furancarboxylic acid, <NUM>-furancarboxylic acid, glycerol, diglycerol, triglycerol or tetraglycerol.

The liquid composition employed in process step II) can moreover comprise as an additive one or more organic binders which are soluble in organic solvents, as described in <CIT> on page <NUM>, lines <NUM>-<NUM>. The liquid composition used for the production of the solid electrolyte layer can have a pH of from <NUM> to <NUM>, and a pH of from <NUM> to <NUM> is preferred. For corrosion-sensitive dielectrics, such as, for example, aluminium oxides or niobium oxides, liquid compositions having a pH of from <NUM> to <NUM> are preferred, in order not to damage the dielectric.

To adjust the pH, for example, bases or acids, as described in <CIT> on page <NUM>, lines <NUM>-<NUM>, can be added as additives to the liquid composition employed in process step II). Those additions which do not impair the film formation of the liquid composition and are not volatile at higher temperatures, e.g. soldering temperatures, but remain in the solid electrolyte under these conditions, such as e.g. the bases <NUM>-dimethylaminoethanol, <NUM>,<NUM>'-iminodiethanol or <NUM>,<NUM>',<NUM>"-nitrilotriethanol and the acid polystyrenesulphonic acid, are preferred.

The viscosity of the liquid composition employed in process step II) can be between <NUM> and <NUM>,<NUM> mPa·s (measured with a rheometer at <NUM> and a shear rate of <NUM>-<NUM>), depending on the method of application. Preferably, the viscosity is <NUM> to <NUM> mPa·s, particularly preferably between <NUM> to <NUM> mPa·s. In the case of the production of aluminium wound capacitors the viscosity is very particularly preferably in a range of from <NUM> to <NUM> mPa·s, while in the production of tantalum electrolytic capacitors or aluminium stacked capacitors it is very particularly preferably in a range of from <NUM> to <NUM> mPa·s. The adjustment of the viscosity can, for example, be accomplished by adding appropriate rheology modifiers as a further additive.

The solids content of the liquid composition employed in process step II) is preferably in a range of from <NUM> to <NUM> wt. %, particularly preferably in a range of from <NUM> to <NUM> wt. % and most preferably in a range of from <NUM> to <NUM> wt. %, in each case based on the total weight of the liquid composition. The solids content of liquid composition is determined via drying of the liquid composition at a temperature which is sufficiently high to remove the solvent c). According to a particularly preferred embodiment of the process for the production of a capacitor the liquid composition that is introduced into the capacitor body not only comprises the functionalized π-conjugated polymer, but - in addition to this self-doped conductive polymer - a foreign doped conductive polymer, preferably PEDOT/PSS, as disclosed in <CIT>.

After the anode bodies have been impregnated with the liquid composition obtainable by the process according to the present invention described above, it is advantageous to at least partially remove the solvent c) contained in the liquid composition in a subsequent process step III), so that a solid electrolyte which completely or partly covers the dielectric, and therefore a capacitor body is formed. In this context it is preferable for the covering of the dielectric by the solid electrolyte to be preferably at least <NUM> %, particularly preferably at least <NUM> % and most preferably at least <NUM> %, it being possible for the covering to be determined by measurement of the capacitance of the capacitor in the dry and in the damp state at <NUM>, as is described in <CIT>.

The removal or hardening is preferably carried out by removing the electrode body from the liquid composition and drying it, the drying preferably being carried out at a temperature in a range of from <NUM> to <NUM>, particularly preferably in a range of from <NUM> to <NUM> and most preferably in a range of from <NUM> to <NUM>. It is, of course, also possible to at least partially remove the solvent c) by freeze drying. Process steps II) and III) can also be repeated once or several times, in order in this manner to adapt the thickness of the layer of the solid electrolyte deposited on the dielectric or the degree of filling of the electrolyte in the electrode body to the particular requirements.

After the capacitor bodies have been produced in this manner, they can be further modified by the method and manner known to the person skilled in the art. In the case of a tantalum electrolytic capacitor, the capacitor bodies can be covered, for example, with a polymeric outer layer, as is described in <CIT> or <CIT>, and/or a graphite layer and a silver layer, as is known from <CIT>, while in the case of an aluminium wound capacitor, in accordance with the teaching of <CIT>, the capacitor body is incorporated into an aluminium beaker, provided with a sealing glass and firmly closed mechanically by crimping. The capacitor can then be freed from defects in the dielectric in a known manner by ageing.

Also disclosed herein is a capacitor which is obtainable, preferably has been obtained, by the above described process. Preferably, this capacitor is a tantalum electrolytic capacitor or an aluminium capacitor, for example an aluminium stacked capacitor or an aluminium wound capacitor.

Also disclosed herein is the use of the liquid composition obtainable by the process according to the present invention, preferably of the liquid composition that has been obtained by the process according to the preset invention, for the preparation of a conductive layer in an electronic device, wherein the electronic device is preferably selected from the group consisting of photoconductive cells, photoresistors, photoswitches, phototransistors, phototubes, IR detectors, photovoltaic device, solar cells, coating materials for memory storage devices, field effect resistance devices, anti-static films, biosensors, electrochromic devices, solid electrolyte capacitors, energy storage devices and electromagnetic shielding. In this context it is particularly preferred that the liquid composition obtainable by the process according to the present invention, preferably the liquid composition that has been obtained by the process according to the preset invention, is used for the preparation of a solid electrolyte layer of a solid electrolyte capacitor. In this context it is particularly preferred to use the liquid composition obtainable by the process according to the present invention, preferably the liquid composition that has been obtained by the process according to the preset invention in a process as disclosed in <CIT>.

The invention is now explained in more detail with the aid of non-limiting figures and examples.

<FIG> is a diagram of a section through a part of a capacitor obtainable by the process for the production of a capacitor. This has an electrode body <NUM>, usually made of a porous electrode material <NUM>, such as aluminium. On the surface <NUM> of the electrode material <NUM>, a dielectric <NUM> is formed as a thin layer, so that an anode body <NUM> which is still porous and comprises the electrode body <NUM> of the electrode material <NUM> and the dielectric <NUM> is formed. The dielectric <NUM> is followed, optionally after further layers, by a layer of a solid electrolyte <NUM> (e.g. a layer that has been prepared using the liquid composition prepared by the process according to the present invention), whereby a capacitor body <NUM> comprising the electrode body <NUM> of the electrode material <NUM>, the dielectric <NUM> and the solid electrolyte <NUM> is formed.

A cleaned glass substrate was laid on a spin coater and <NUM> of the liquid composition was distributed over the substrate. The remaining solution was then spun off by rotation of the plate. Thereafter, the substrate thus coated was dried for <NUM> minutes at <NUM> on a hot plate. The layer thickness was then determined by means of a layer thickness measuring device. (Tencor, Alphastep <NUM>). The conductivity was determined in that Ag electrodes of <NUM> length were vapour deposited at a distance of <NUM> via a shadow mask. The surface resistance determined with an electrometer (Keithly <NUM>) was multiplied by the layer thickness in order to obtain the specific electrical resistivity. The conductivity is the inverse of the specific electrical resistivity.

The oxygen content is measured with a Knick Portamess <NUM> Oxy (Knick Elektronische Messgeräte GmbH & Co. KG, Beuckestraße <NUM>, Berlin, Germany). Prior to measurement the device is calibrated against ambient air. To determine the oxygen content at the beginning of the reaction the sensor is immersed under nitrogen flow into the reaction solution.

The chloride content was determined by ion chromatography using the following equipment and measuring conditions:.

For calibration the following standard is used: "Chlorid-Standardläsung, <NUM>/l Cl- in Wasser (aus NaCl) ARISTAR® Standard für die Ionenchromatographie", VWR Product code 458012Q <NUM> (VWR International GmbH, Darmstadt). For calibration a concentration series is done by diluting the standard with deionized water in order to calibrate the Ion Chromatography in the relevant range of <NUM> to <NUM> ppm. If the chloride content of the sample is higher than <NUM> ppm the sample is diluted with deionized water until the chloride concentration fits into the calibration range. The result is multiplied by the dilution factor in order to calculate the chloride content of the original sample.

The equivalent series resistance (in mΩ) was determined at <NUM> at <NUM> by means of an LCR meter (Agilent 4284A). In each capacitor experiment at least <NUM> capacitors have been prepared and the average ESR-value was determined.

The capacitance (in µF) was determined at <NUM> at <NUM> by means of an LCR meter (Agilent 4284A). In each capacitor experiment at least <NUM> capacitors have been prepared and the average capacitance-value was determined.

If not otherwise mentioned, the average corresponds to the arithmetical average value.

For the preparation of a PEDOT-S solutions as described below, the sodium salt of <NUM>-(<NUM>,<NUM>-dihydrothieno-[<NUM>,<NUM>-b][<NUM>,<NUM>]dioxin-<NUM>-ylmethoxy)-<NUM>-butanesulphonic acid (EDOT-S) was prepared as described by <NPL>) and employed as the monomer.

A <NUM> jacketed beaker made of glass is equipped a mechanical stirrer, a thermometer and a nitrogen flow.

In this beaker <NUM> (<NUM> mol) iron(III)chloride were dissolved in <NUM> of deionized water and nitrogen was blown through the solution for <NUM> minutes while stirring until the oxygen content was below <NUM>/l.

In a separate glass beaker <NUM> EDOT-S sodium salt (<NUM> mol) were dissolved in <NUM> of deionized water. Nitrogen was blown through this solution via a flexible tube until the oxygen content was below <NUM>/l.

Component B was added to component A while stirring. The thus obtained mixture was heated up to <NUM>-<NUM> within <NUM> hours and was kept at this temperature for additional <NUM> hours. After the reaction was completed, the reaction mixture was filled up to a volume of <NUM> by adding deionized water and was subsequently treated by means of ultrafiltration (Pall Microza SLP <NUM> with a cut-off of <NUM>/mol), whereby <NUM> of water were removed. This procedure was repeated <NUM> times in order to remove the inorganic salts.

The thus obtained dispersion was characterized by a conductivity of <NUM>/cm and a solid content of <NUM> wt.

A <NUM> jacketed tank made of stainless steel is equipped a mechanical stirrer, a ventilation valve at the upper lid, a material inlet that can be closed and a thermometer.

Into this tank <NUM> of deionized water, <NUM> of a <NUM> wt. -% aqueous iron(III) sulfate solution and <NUM> of EDOT-S sodium salt (<NUM> mol) were introduced. The stirrer was operated at <NUM> rpm, the temperature was adjusted to <NUM> and the inner pressure was reduced to <NUM> hPa. The pressure in the tank was subsequently raised to atmospheric pressure, followed by a further reduction of a pressure to <NUM> hPa in order to expel the oxygen.

In a separate glass beaker <NUM> sodium peroxodisulfate were dissolved in <NUM> water and nitrogen was blown through the solution for <NUM> minutes while stirring until the oxygen content was below <NUM>/l.

Component B was then sucked into the tank. The material inlet was then closed and the inner pressure of the tank was adjusted to <NUM> hPa by means of a vacuum pump. The reaction was continued for <NUM> hours under this reduced pressure. After the reaction was completed, the reaction mixture was filled up to a volume of <NUM> by adding deionized water and was subsequently treated by means of ultrafiltration (Pall Microza SLP <NUM> with a cut-off of <NUM>/mol), whereby <NUM> of water were removed. This procedure was repeated <NUM> times in order to remove the inorganic salts.

Into this tank <NUM> of deionized water, <NUM> of a <NUM> wt. -% aqueous iron(III) sulfate solution, <NUM> sulfuric acid (<NUM> wt. -%) and <NUM> of EDOT-S sodium salt (<NUM> mol) were introduced. The stirrer was operated at <NUM> rpm, the temperature was adjusted to <NUM> and the inner pressure was reduced to <NUM> hPa. The pressure in the tank was subsequently raised to atmospheric pressure, followed by a further reduction of a pressure to <NUM> hPa in order to expel the oxygen.

Component B was then sucked into the tank. The material inlet was then closed and the inner pressure of the tank was adjusted to <NUM> hPa by means of a vacuum pump. The initial pH of the reaction solution was <NUM> and the reaction was continued for <NUM> hours under this reduced pressure. After the reaction was completed, the reaction mixture was filled up to a volume of <NUM> by adding deionized water and was subsequently treated by means of ultrafiltration (Pall Microza SLP <NUM> with a cut-off of <NUM>/mol), whereby <NUM> of water were removed. This procedure was repeated <NUM> times in order to remove the inorganic salts.

The thus obtained composition was characterized by a conductivity of <NUM>/cm and a solid content of <NUM> wt. The composition was further concentrated by means of ultra filtration until a solid content of <NUM> wt. -% was reached.

<NUM> of deionized water and <NUM> of an aqueous polystyrenesulphonic acid solution having an average molecular weight of <NUM>,<NUM>/mol and a solids content of <NUM> wt. % were initially introduced into a <NUM> three-necked flask with a stirrer and internal thermometer. The reaction temperature was kept between <NUM> and <NUM>. <NUM> of <NUM>,<NUM>-ethylenedioxythiophene were added, while stirring. The solution was stirred for <NUM>. <NUM> of iron(III) sulphate and <NUM> of sodium persulphate were then added and the solution was stirred for a further <NUM>. After the reaction had ended, for removal of inorganic salts <NUM> of a strongly acid cation exchanger and <NUM> of a weakly basic anion exchanger were added and the solution was stirred for a further <NUM>. The ion exchanger was filtered off. The poly(<NUM>,<NUM>-ethylenedioxy-thiophene)/polystyrenesulphonate dispersion was homogenized with a high pressure homogenizer ten times under a pressure of <NUM> bar. The dispersion was subsequently concentrated to a solids content of <NUM> % and then additionally homogenized another five times under a pressure of <NUM>,<NUM> bar.

<NUM> of EDOT-S (<NUM> mmol) were dissolved in <NUM> of dist. water under argon. <NUM> (<NUM> mmol) of FeCl<NUM> was then added in one portion. Thereafter, the solution was stirred at room temperature for <NUM>, and heated at <NUM> for <NUM>, cooled and worked up. For working up, the solution was diluted to about <NUM> wt. % with dist. water, <NUM> of Lewatit® S100 and <NUM> of Lewatit® MP <NUM> were added and the mixture was stirred at room temperature for <NUM>. After the ion exchangers had been filtered off, a dark blue polymer solution having a solids content of <NUM> % was obtained.

<NUM> of the PEDOT/PSS dispersion from Synthesis Example <NUM>, <NUM> of the PEDOT-S composition from Synthesis Example <NUM> and <NUM> of polyethylene glykol <NUM> (PEG-<NUM>) were mixed and the pH was adjusted to <NUM> using ammonia (dispersion A).

A porous aluminium foil, formed at <NUM> V, having dimensions of <NUM> × <NUM> (anode foil) and a porous aluminium foil having dimensions of <NUM> × <NUM> (cathode foil) were each provided with a contact wire and were then wound up together with two cellulose separator papers and fixed with an adhesive tape. <NUM> of these oxidized electrode bodies were produced. The separator paper of the oxidized electrode bodies was then carbonized in an oven at <NUM>. The oxidized electrode bodies were impregnated in dispersion A for <NUM> minutes. Thereafter, drying was carried out at <NUM> for <NUM> and then at <NUM> for <NUM>. The impregnation and drying were carried out a further time. The mean electrical values are shown in Table <NUM>.

<NUM> of the PEDOT/PSS dispersion from Synthesis Example <NUM>, <NUM> of the PEDOT-S composition from Synthesis Example <NUM> and <NUM> of polyethylene glykol <NUM> (PEG-<NUM>) were mixed and the pH was adjusted to <NUM> using ammonia (dispersion B).

Capacitors were prepared pursuant to the procedure in Comparative Example <NUM>. The mean electrical values are shown in Table <NUM>, wherein the values were normalized to the Comparative Example <NUM>.

<NUM>,<NUM> of deionized water and <NUM> of an aqueous polystyrenesulphonic acid solution having an average molecular weight of <NUM>,<NUM>/mol and a solids content of <NUM> wt. % were initially introduced into a <NUM><NUM> glass reactor with a stirrer and thermometer. The reaction temperature was kept between <NUM> and <NUM>. <NUM> of <NUM>,<NUM>-ethylenedioxythiophene were added, while stirring. The solution was stirred for <NUM> minutes. <NUM> of iron(III) sulphate and <NUM> of sodium persulphate were then added and the solution was stirred for a further <NUM> hours. After the reaction had ended, for removal of inorganic salts <NUM> of a strongly acid cation exchanger and <NUM> of a weakly basic anion exchanger were added and the solution was stirred for a further <NUM>. The ion exchanger was filtered off. The dispersion obtained achieved a solids content of <NUM> % by subsequent concentration.

<NUM> of this dispersion, <NUM> of water, <NUM> of a sulpho-polyester (Eastek <NUM>, solids content <NUM> %, average molecular weight <NUM>,<NUM> - <NUM>,<NUM>, Eastman), <NUM> of dimethylsulphoxide, <NUM> of <NUM>-glycidoxypropyltrimethoxysilane (Silquest A- <NUM>, OSi Specialties) and <NUM> of wetting agent (Dynol <NUM>, Air Products) were mixed intensively for one hour in a glass beaker with a stirrer.

<NUM> of p-toluenesulphonic acid monohydrate, <NUM> of <NUM>,<NUM>-diaminodecane and <NUM> of water were mixed intensively in a glass beaker with a stirrer.

Tantalum powder having a specific capacitance of <NUM>,<NUM> CV/g was pressed to pellets with inclusion of a tantalum wire and sintered in order to form a porous anode body having dimensions of <NUM> × <NUM> × <NUM>. <NUM> of these porous anode bodies were anodized in a phosphoric acid electrolyte at <NUM> V to form a dielectric, in order to obtain the capacitor bodies.

The composition from Synthesis Example <NUM> was diluted to a concentration of <NUM> % by addition of deionized water.

The capacitor bodies from Synthesis Example <NUM> were impregnated in the composition from Synthesis Example <NUM> for <NUM>. Thereafter, drying was carried out at <NUM> for <NUM>. The impregnation and drying were carried out nine further times.

The capacitor bodies were then impregnated in the solution from Synthesis Example <NUM>. Thereafter, drying was carried out at <NUM> for <NUM>. The capacitor body was then impregnated in the dispersion from Synthesis Example <NUM>. Thereafter, drying was carried out at <NUM> for <NUM>.

The capacitor bodies were then covered with a graphite layer and thereafter with a silver layer in order to obtain the finished capacitors in this way.

The mean values for the electrical parameters (CAP, ESR) are shown in Table <NUM>.

The treatment of the capacitor bodies was carried out as described in Comparative Example <NUM>, but the composition from Synthesis Example <NUM> was used instead of the composition from Synthesis Example <NUM>.

The mean values for the electrical parameters (CAP, ESR) are shown in table <NUM>, wherein the values were normalized to the Comparative Example <NUM>.

Claim 1:
A process for producing a liquid composition comprising functionalized π-conjugated polythiophenes, the process comprising the steps of
i) providing a liquid phase comprising
a) thiophene monomers of the general formula (I)
<CHM>
wherein
X,Y are identical or different and are O, S, or NR<NUM>, wherein R<NUM> is hydrogen or an aliphatic or aromatic residue having <NUM> to <NUM> carbon atoms;
A is an organic residue carrying an anionic functional group selected from the group consisting of -CO<NUM>-, -SO<NUM>- and -OSO<NUM>-.,
b) an oxidizing agent; and
c) a solvent;
ii) oxidatively polymerizing the thiophene monomers of the general formula (I) to obtain a liquid composition comprising functionalized π-conjugated polythiophenes;
wherein
(α1) the pH of the liquid phase provided in process step i) is adjusted to a value below <NUM>, wherein the pH is determined at a temperature of <NUM>, wherein an inorganic or organic acid is used for the adjustment of the pH; and
(α2) the chloride content of the liquid phase provided in process step i) is less than <NUM>,<NUM> ppm, based on the total weight of the liquid phase.