Title of Invention	A NON POLAR METAL ELECTROLYTIC CAPACITOR AND METHOD OF MANUFACTURING THEREOF
Abstract	A nonpolar metal electrolytic capacitor in which an electric conductivity is significantly improved by applying a metal material, instead of a solid electrolyte and electrolyte of an aluminum electrolytic capacitor, and a manufacturing method thereof is provided. A nonpolar metal electrolytic capacitor 10 includes a metal foil 11 including a plurality of groovesl la arranged on both surfaces of the metal foil 11, a metal oxide film 12 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a, a lead terminal 15 being installed in the main electrode layer 14, and a molding member 16 being provided so that the lead terminal 15 is externally protruded from the molding member 16, and the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14 are sealed.

Title of Invention

A NON POLAR METAL ELECTROLYTIC CAPACITOR AND METHOD OF MANUFACTURING THEREOF

Abstract

A nonpolar metal electrolytic capacitor in which an electric conductivity is significantly improved by applying a metal material, instead of a solid electrolyte and electrolyte of an aluminum electrolytic capacitor, and a manufacturing method thereof is provided. A nonpolar metal electrolytic capacitor 10 includes a metal foil 11 including a plurality of groovesl la arranged on both surfaces of the metal foil 11, a metal oxide film 12 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a, a lead terminal 15 being installed in the main electrode layer 14, and a molding member 16 being provided so that the lead terminal 15 is externally protruded from the molding member 16, and the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14 are sealed.

Full Text	FORM 2 THE PATENT ACT 1970 (39 of 1970) & The Patents Rules, 2003 COMPLETE SPECIFICATION (See section 10 and rule 13) 1. Metal Electrolytic Capacitor and method manufacturing thereof 2. (A) OH, Young Joo (B) Korea. (C) 201ho,Doosan Villa (D) 116-2 Cheongdam-dong Gangnam-gu Seoul 135-100 Republic of Korea The following specification particularly describes the invention and the manner in which it is to be performed. [Technical Field] The present invention relates to a nonpolar metal electrolytic capacitor in which an electric conductivity is significantly improved by applying a metal material, instead of a solid electrolyte and electrolyte of an aluminum electrolytic capacitor, and a manufacturing method thereof. [Background Art] An aluminum electrolytic capacitor is used for a flow frequency bypass or a smoothing circuit of a power source. Hereinafter, a method of manufacturing the aluminum electrolytic capacitor will be briefly described. An etching process on an aluminum foil is performed to enlarge a surface area of the aluminum foil and thereby increase an electric capacity. When the etching process is completed, a forming process of forming a dielectric substance on the aluminum foil is performed whereby cathode and anode aluminum foils are manufactured to be used for assembly of the aluminum electrolytic capacitor. When the etching process and the forming process are completed, a slitting process of cutting the completed aluminum foil and a separator by as long as a desired width based on the length of a product is performed. When the slitting process is completed, a stitching process of stitching an aluminum lead patch, which is a lead terminal, to the aluminum foil is performed. When the slitting of the aluminum foil and the separator is completed, a winding process of disposing the separator between the anode aluminum foil and the cathode aluminum foil, and then winding the separator and the aluminum foils in a cylindrical shape and attaching a tape thereto, so as to not be unwounded. When the winding process is completed, an impregnation and curling process of disposing the wound device into an aluminum case, injecting an electrolyte, and curling the aluminum and a sealing material is performed. When the curling process is completed, an aging process of restoring a damage to the dielectric substance is performed whereby assembly of the aluminum electrolytic capacitor is completed. Due to the current development in digitalization and thinness of electronic devices, when applying the conventional aluminum electrolytic capacitor, there are some problems as follow. Since the aluminum electrolytic capacitor uses the electrolyte, an electric conductivity is comparatively low and thus there is some constraint on a long life of the aluminum electrolytic capacitor in a high frequency area. Also, there are some constraints on improvement of reliability, a high frequency response, a low equivalent series resistance (ESR), and impedance. Also, due to a comparatively high ripple pyrexia, there are some constraints on stability and environments, such as fuming and firing. [Disclosure] [Technical Problem] The present invention is conceived to solve the above-described problems and thus provides a nonpolar metal electrolytic capacitor in which an electric conductivity is improved by about 10,000 to 1,000,000 folds by applying a metal material for an electrolyte, in comparison to when using a conventional electrolyte or an organic semiconductor, a nonpolar multi-layer metal electrolytic capacitor using the same, and a manufacturing method thereof. The present invention also provides a nonpolar metal electrolytic capacitor which can improve a thinness, a low equivalent series resistance (ESR), a reduction in a ripple pyrexia, a long life, a heat-resistant stability, non-fuming, non-firing, and environment by using a metal material for an electrolyte, a nonpolar multi-layer metal electrolytic capacitor using the same, and a manufacturing method thereof. The present invention also provides a nonpolar metal electrolytic capacitor which can be simply provided in a multi-layer by using a metal material for an electrolyte, which is impossible in a conventional aluminum electrolytic capacitor structure, a nonpolar multi-layer metal electrolytic capacitor using the same, and a manufacturing method thereof. [Technical Solution] According to an aspect of the present invention, there is provided a nonpolar metal electrolytic capacitor including: a metal foil including a plurality of grooves arranged on both surfaces of the metal foil; a metal oxide film being formed on the plurality of grooves formed on the metal foil; a seed electrode layer being formed on the metal oxide film, and a main electrode layer being formed on the seed electrode layer to fill the plurality of grooves; a lead terminal being installed in the main electrode layer; and a molding member being provided so that the lead terminal is externally protruded from the molding member, and the metal foil, the metal oxide film, the seed electrode layer, and the main electrode layer are sealed. According to another aspect of the present invention, there is provided a method of manufacturing a nonpolar metal electrolytic capacitor, the method including: an etching process of arranging a plurality of grooves on both surfaces of a metal foil by using a direct current (DC) etching method; a forming process of forming a metal oxide film on the metal foil by using an anodic oxidation method when the plurality of grooves is formed on the metal foil; a process of forming a seed electrode layer to be penetrated into the metal oxide film by using a chemical vapor deposition (CVD) method when the metal oxide film is formed; a process of forming a main electrode layer to fill the plurality of grooves formed on the metal foil via the seed electrode layer as a medium by using a plating method when the seed electrode layer is formed; a process of forming a lead terminal on the main electrode layer when the main electrode layer is formed; and a molding process of sealing the metal foil so that the lead terminal is externally protruded when the lead terminal is formed. [Advantageous Effects] As described above, according to the present invention, there is provided a nonpolar metal electrolytic capacitor in which an electric conductivity is improved by about 10,000 to 1,000,000 folds by applying a metal material for an electrolyte, in comparison to when using a conventional electrolyte or an organic semiconductor. In this instance, the nonpolar metal electrolytic capacitor may be provided in a serial multi-layer type and thus may be used in a high voltage. Also, the nonpolar metal electrolytic capacitor is nonpolar and thus has no directivity and has a high stability. Also, it is possible to improve a thinness, a low ESR, a heat-resistant stability, non-fuming, non-firing, and environment Although the present invention has been described in connection with the embodiment of the present invention shown in the accompanying drawings, it is not limited thereto since it will be apparent to those skilled in the art that various substitutions, modifications and changes may be made thereto without departing from the scope and spirits of the invention. [Description of Drawings] FIG. 1 is a cross-sectional view illustrating a nonpolar metal electrolytic capacitor according to the present invention; FIG. 2 is a cross-sectional view illustrating a nonpolar multi-layer metal electrolytic capacitor according to the present invention; and FIGS. 3A through 3G are cross-sectional views illustrating a method of manufacturing a nonpolar metal electrolytic capacitor and a nonpolar multi-layer metal electrolytic capacitor according to the present invention. [Best Mode] Hereinafter, the first embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a cross-sectional view illustrating a nonpolar metal electrolytic capacitor 10 according to the present invention. As shown in FIG. 1, the nonpolar metal electrolytic capacitor 10 includes a metal foil 11 including a plurality of grooveslla arranged on both surfaces of the metal foil 11, a metal oxide filml2 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a, a lead terminal 15 being installed in the main electrode layer 14, and a molding member 16 being provided so that the lead terminal 15 is externally protruded from the molding member 16, and the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14 are sealed. A configuration of the nonpolar metal electrolytic capacitor 10 will be further described in detail. As shown in FIG. 1, the nonpolar metal electrolytic capacitor 10 includes the metal foil 11, the metal oxide film 12, the seed electrode layer 13, the main electrode layer 14, the lead terminal 15, and the molding member 16. Hereinafter, a configuration thereof will be sequentially described. The plurality of grooves 11a is arranged on the both surfaces of the metal foil 11 to increase a surface area. In this instance, aluminum (Al) material is used. Also, each of the plurality of grooves 11a (shown in FIG. 3B) formed on the metal foil 11 has a width (a, b: shown in 3B) of 0.1 to 5 , and a height (c: shown in FIG. 3B) of 10 to 100 . The width of the groove 11a may be, preferably, 1 and the height of the groove 11a may be, preferably, 40 The metal oxide film 12 is formed on the plurality of grooves 11a arranged on the metal foil 11. In this instance, the metal oxide film 12 is formed of alumina (AI2O3). Also, when alumina (A1A) is applied for the metal foil 11, the metal foil 11 is formed by oxidizing the surface alumina (A1203). The seed electrode layer 13 corresponds to a portion where small cylindrical shapes are arranged, as shown in FIG. 1, and is formed on the metal oxide film 12. In this instance, the seed electrode layer 13 is formed to be penetrated into the metal oxide film 12 by using any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). The main electrode layer 14 is formed on the seed electrode layer 13 to fill the plurality of grooves 11a, and uses any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). Also, a conductive adhesive layer 17 is further provided on the main electrode layer 14 before installing the lead terminal 15 in the main electrode layer 14. In this instance, the conductive adhesive layer 17 is formed using a solder paste, electroless plating or electrolytic plating. The conductive adhesive layer 17 is provided to improve an adhesive strength and an adhering process. The lead terminal 15 is installed in the main electrode layer 14. In FIG. 1, the lead terminal 15 is installed in the conductive adhesive layer 17. However, when the conductive adhesive layer 17 is not provided, the lead terminal 15 is installed in the main electrode layer 14 with a mechanical force using a high pressure. The molding member 16 uses epoxy molding compound (EMC). In this instance, when the lead terminal 15 is installed in either the main electrode layer 14 or the conductive adhesive layer 17, the molding member 16 is provided to seal the metal foil 11, the metal oxide film 12, the seed electrode layer 13, ad the main electrode layer 14 while the lead terminal 15 is externally protruded. Also, the molding member 16 may be molded in a planar shape as shown in FIG. 1. Also, the molding member 16 may be molding in a cylindrical shape (not shown). When the molding member 16 is molded in the cylindrical shape, the metal foil 11 is molded in a wound state like the conventional aluminum condenser. Hereinafter, the second embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 2 is a cross-sectional view illustrating a nonpolar multi-layer metal electrolytic capacitor 100 according to the present invention. As shown in FIG. 2, the nonpolar multi-layer metal electrolytic capacitor 100 includes: a plurality of first to nth metal electrolytic foils 10a, 10b, •••, lOn, wherein each of the metal electrolytic foils 10a, 10b, •••, lOn includes a metal foil 11 including a plurality of grooves 11a arranged on both surfaces of the metal foil 11, a metal oxide film 12 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a; a lead terminal 15 being installed in the main electrode layer 14 which is located on an outer portion of each of the first metal electrolytic foil 10a and the nth metal electrolytic foil lOn among the first to the n,h metal electrolytic foil 10a, 10b, •••, lOn; and a molding member 16 being provided so that the lead terminal 15 is externally protruded and the first to the nth metal electrolytic foils 10a, 10b, •••, lOn is sealed. A configuration of the nonpolar multi-layer metal electrolytic capacitor 100 will be further described in detail. As shown in FIG. 2, the nonpolar multi-layer metal electrolytic capacitor 100 includes the first to the nl metal electrolytic foils 10a, 10b, •••, lOn, the lead terminal 15, and the molding member 16. Hereinafter, a configuration thereof will be sequentially described. Each of the first to the nth metal electrolytic foils 10a, 10b, •••, lOn includes the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14. The configuration thereof is the same as the configuration of the nonpolar metal electrolytic capacitor 10 according to the first embodiment and thus will be briefly described. The plurality of grooves 11a is arranged on the both surfaces of the metal foil 11 and is formed of aluminum (Al). Also, the metal oxide film 12 is formed on the plurality of grooves 11a arranged on the metal foil 11, and is formed of alumina (A1203). Also, the seed electrode layer 13 is formed on the metal oxide film 12, and the main electrode layer 14 is formed on the seed electrode layer 13 to fill the plurality of grooves 11a. In this instance, each of the seed electrode layer 13 and the main electrode layer 14 uses any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). Also, a conductive adhesive layer 17 is further provided on the main electrode layer 14. Accordingly, when providing the first to the nth metal electrolytic foils 10a, 10b, •••, lOn in a multi-layer structure or when installing the lead terminal 15, an adhesive strength may be improved. The conductive adhesive layer 17 is formed using a solder paste, electroless plating or electrolytic plating. The nonpolar multi-layer metal electrolytic capacitor 100 may be formed in a serial multi-layer type to be used for a high-voltage and a low capacity. When providing the nonpolar multi-layer metal electrolytic capacitor 100 in the serial multi-layer type, the lead terminal 15 is installed in the main electrode layer 14 which is located on an outer portion of each of the first metal electrolytic foil 10a and the nl metal electrolytic foil lOn among the first to the nl metal electrolytic foils 10a, 10b, •••, lOn. In this instance, when the conductive adhesive layer 17 is not provided to the first to the nth metal electrolytic foil 10a, 10b, •••, lOn, the lead terminal 15 is directly installed in the main electrode layer 14. When the conductive adhesive material 17 is provided, the lead terminal 15 is installed in the conductive adhesive layer 17. In this instance, when the conductive adhesive layer 17 is not provided, each of the first to the nth metal electrolytic foil 10a, 10b, •••, lOn is provided in a multi-layer by a mechanical force using a high pressure. Also, the nonpolar multi-layer metal electrolytic capacitor 100 may be provided in a parallel multi-layer type to be used for a low-voltage and a high capacity. When providing the nonpolar multi-layer metal electrolytic capacitor 100 in the parallel multi-layer type, the lead terminal 15 is installed as shown in FIG. 2 using a dotted line. Specifically, the lead terminal 15 is installed to be withdrawn to one side of the main electrode layer 14 of each of a plurality of odd number th metal electrolytic foils 10a, •••, 10n-l, and to be withdrawn to another side of the main electrode layer 14 of each of a plurality of even number th metal electrolytic foils 10b, •••, lOn among the plurality of first to nth metal electrolytic foils 10a, 10b, •••, lOn. When the lead terminal 15 is installed in the first to the nth metal electrolytic foils 10a, 10b, •••, lOn, the molding member 16 is provided. In this instance, the molding member 16 is provided so that the lead terminal 16 may be externally protruded, and the first to the nth metal electrolytic foils 10a, 10b, •••, lOn may be sealed. When sealing the first to the nth metal electrolytic foils 10a, 10b, •••, lOn, the molding member molds the first to the nth metal electrolytic foils 10a, 10b, •••, lOn in a planar shape or a cylindrical shape (not shown). Also, in the case of molding the first to the n* metal electrolytic foils 10a, 10b, •••, lOn in the cylindrical shape, the molding member 16 winds and molds the first to the nth metal electrolytic foils 10a, 10b, ••*, lOn. Hereinafter, a method of manufacturing the nonpolar metal electrolytic capacitor 10 according to the first embodiment and the nonpolar multi-layer metal electrolytic capacitor 100 according to the second embodiment, constructed as above, will be described with reference to the accompanying drawings. Firstly, a method of manufacturing the nonpolar metal electrolytic capacitor 10 according to the first embodiment will be described with reference to FIGS. 3A through 3F. As shown in FIGS. 3A and 3B, an etching process of forming a plurality grooves 11a on both surfaces of a metal foil 11, formed of aluminum (Al), by using an electrochemical method, that is, a direct current (DC) etching method is performed to increase a surface area of the metal foil 11. When the plurality of grooves 11a is formed on the metal foil 11, a forming process of forming a metal oxide film 12, formed of alumina (A1203), on the metal foil 11 by using an anodic oxidation method is performed as shown in FIG. 3C. In this instance, the anodic oxidation is performed so that a proper voltage of a capacitor may be 140% to 160% of 6. 3 V to 500V. As shown in FIGS. 3D and 3E, when the metal oxide film 12 is formed, a process of forming a seed electrode layer to be penetrated into the metal oxide film 12 and thereby grow by using any one of a chemical vapor deposition (CVD) method, a thermal evaporation method, and a molecular layer growth method is performed. In this instance, the molecular growth method uses a metal organic CVD method. As shown in FIG. 3F, when the seed electrode layer 13 is formed, a process of forming a main electrode layer 14 to fill the plurality of grooves 11a formed on the metal foil 11 via the seed electrode layer 13 as a medium by using electroless plating or electrolytic plating (AC: alternative current, DC: direct current) is performed. In this instance, the seed electrode layer 13 or the main electrode layer 14 may use any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). Also, when the main electrode layer 14 is formed in the process of forming the main electrode layer 14, a process of forming a conductive adhesive layer 17 on the main electrode layer 14 may be further performed. In this instance, the conductive adhesive layer 17 is provided to improve an adhesive strength and is formed by using a solder paste, electroless plating or electrolytic plating. As shown in FIG. 1, when the main electrode layer 14 is formed, a process of forming the lead terminal 15 on the main electrode layer 14 is performed. Also, a molding process of sealing the metal foil 11 so that the lead terminal 15 is externally protruded is performed. Through the above process, the nonpolar metal electrolytic capacitor 10 is manufactured. The metal foil 11 may be molded in a planar shape or a cylindrical shape in the molding process. Hereinafter, a method of manufacturing the nonpolar multi-layer metal electrolytic capacitor 100 according to the second embodiment will be described. In the method of manufacturing the nonpolar multi-layer metal electrolytic capacitor 100, an etching process of forming a plurality grooves 11a on both surfaces of a metal foil 11, formed of aluminum (Al), by using a direct current (DC) etching method through a process of forming a main electrode layer 14 to fill the plurality of grooves 11a formed on the metal foil 11 via the seed electrode layer 13 as a medium are the same as the manufacturing process of the nonpolar metal electrolytic capacitor according to the first embodiment, and thus will be omitted here. When the main electrode layer 14 is formed through the processes as shown in FIGS. 3A through 3F, a process of forming first to n metal electrolytic foils 10a, 10b, •••, lOn by cutting the metal foil 11 formed on the main electrode layer 14. As shown in FIG. 3G, when the first to the nth metal electrolytic foils 10a, 10b, •••, lOn are formed, a process of forming a metal electrolytic foil multi-layer body 100a by pressing first to the nth metal electrolytic foils 10a, 10b, •••, lOn with a high pressure is performed. When forming the metal electrolytic foil multi-layer body 100a, the plurality of the first to the nth metal electrolytic foils 10a, 10b, •••, lOn may be formed by repeating the etching process through the process of forming the main electrode layer 14, or formed by using the plurality of metal electrolytic foils 10a, 10b, •••, lOn, which is formed by cutting the metal foil 11 including the main electrode layer 14, or the plurality of metal electrolytic foils 10a, 10b, •••, lOn, which is formed by repeating the etching process through the process of forming the main electrode layer 14. When the metal electrolytic foil multi-layer body 100a is formed, a process of forming the lead terminal 15, as shown in FIG. 15, on the main electrode layer 14, which is located on an outer portion of each of the first metal electrolytic foil 10a and the nth metal electrolytic foil lOn of the metal electrolytic foil multi-layer body 100a, is performed. When forming the lead terminal on the main electrode layer 14 which is located on the outer portion of the first metal electrolytic foil 10a and the nth metal electrolytic foil lOn, it is possible to use the nonpolar multi-layer metal electrolytic capacitor 100, which is in the serial multi-layer shape, for a high-voltage and a small capacity. Also, when using the nonpolar multi-layer metal electrolytic capacitor 100 for a low voltage and a high capacity, the lead terminal 15, in the process of forming the lead terminal 15, is formed to be withdrawn to one side of the main electrode layer 14 of each of a plurality of odd numberth metal electrolytic foils and 10a, •••, 10n-l, to be withdrawn to another side of the main electrode layer 14 of each of a plurality of even numberth metal electrolytic foils 10b, •••, lOn, among the plurality of first to nth metal electrolytic foils 10a, 10b, •••, lOn, in order to provide the nonpolar multi-layer metal electrolytic capacitor 100 in a parallel multi-layer type. When providing the first to the nth metal electrolytic foils 10a, 10b, •••, lOn in either the serial multi-layer type or the parallel multi-layer type, it is possible to improve an adhesive strength and an adhering process between the lead terminal 15 and the first to the nth metal electrolytic foils 10a, 10b, •••, lOn by using the conductive adhesive layer 17, which is the same as the method of manufacturing the nonpolar metal electrolytic capacitor 10. In this instance, the conductive adhesive layer 17 is formed using a solder paste, electroless plating or electrolytic plating. When the conductive adhesive layer 17 is not provided, the first to the nth metal electrolytic foils 10a, 10b, •••, lOn are pressed by a mechanical force using a high pressure and thereby provided in a multi-layer. When the first to the nth metal electrolytic foils 10a, 10b, •••, lOn are provided in the serial multi-layer type or the parallel multi-layer type by the mechanical force or the conductive adhesive layer 17, a molding process of sealing the metal electrolytic foil multi-layer body 100a so that the lead terminal 15 is externally protruded is performed. Through the above process, the manufacturing process of the nonpolar multi-layer metal electrolytic capacitor 100 is completed. When molding the first to the nth metal electrolytic foils 10a, 10b, •••, lOn during the molding process, the first to the nth metal electrolytic foils 10a, 10b, •••, lOn may be molded in a planar shape or a cylindrical shape. [Industrial Applicability] The present invention may be applied to a nonpolar metal electrolytic capacitor in which an electric conductivity is improved by about 10,000 to 1,000,000 folds by applying a metal material for an electrolyte, in comparison to when using a conventional electrolyte or an organic semiconductor, a nonpolar multi-layer metal electrolytic capacitor using the same, and a manufacturing method thereof. I Claim: [Claim 1] A nonpolar metal electrolytic capacitor comprising: a metal foil including a plurality of grooves arranged on both surfaces of the metal foil; a metal oxide film being formed on the plurality of grooves formed on the metal foil; a seed electrode layer being formed on the metal oxide film, and a main electrode layer being formed on the seed electrode layer to fill the plurality of grooves; a lead terminal being installed in the main electrode layer; and a molding member being provided so that the lead terminal is externally protruded from the molding member, and the metal foil, the metal oxide film, the seed electrode layer, and the main electrode layer are sealed. [Claim 2] The nonpolar metal electrolytic capacitor of claim 1, wherein each of the plurality of grooves formed on the metal foil has a width of about 0. 1 to about 5 . [Claim 3] The nonpolar metal electrolytic capacitor of claim 1, wherein each of the plurality of grooves formed on the metal foil has a height of about 10 to about 100 . [Claim 4] The nonpolar metal electrolytic capacitor of claim 1, wherein the metal foil is made of aluminum (Al). [Claim 5] The nonpolar metal electrolytic capacitor of claim 1, wherein the metal oxide film includes alumina (A1203). [Claim 6] The nonpolar metal electrolytic capacitor of claim 1, wherein the seed electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 7] The nonpolar metal electrolytic capacitor of claim 1, wherein the main electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 8] The nonpolar metal electrolytic capacitor of claim 1, wherein the main electrode layer further comprises a conductive adhesive layer. [Claim 9] The nonpolar metal electrolytic capacitor of claim 1, wherein the molding member molds the metal foil, including the main electrode layer, into either a planar shape or a cylindrical shape, and in the case of molding the metal foil in the cylindrical shape, winds and molds the metal foil. [Claim 10] A nonpolar multi-layer metal electrolytic capacitor comprising: a plurality of first to nth metal electrolytic foils, wherein each of the metal electrolytic foils comprises a metal foil including a plurality of grooves arranged on both surfaces of the metal foil, a metal oxide film being formed on the plurality of grooves formed on the metal foil, a seed electrode layer being formed on the metal oxide film, and a main electrode layer being formed on the seed electrode layer to fill the plurality of grooves; a lead terminal being installed in the main electrode layer which is located on an outer portion of each of the first metal electrolytic foil and the nth metal electrolytic foil among the first to the nth metal electrolytic foil; and a molding member being provided so that the lead terminal is externally protruded and the first to the nth metal electrolytic foils is sealed. [Claim 11] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the metal oxide film of each of the first to the nth metal electrolytic foils is made of aluminum (Al). [Claim 12] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the metal oxide film of each of the first to the nth metal electrolytic foils includes alumina (A1203). [Claim 13] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the seed electrode layer of each of the first to the nth metal electrolytic foils uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 14] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the main electrode layer of each of the first to the nth metal electrolytic foils uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 15] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein a conductive adhesive layer is further disposed between the plurality of first to n" metal electrolytic foils. [Claim 16] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the lead terminal is installed to be withdrawn to one side of the main electrode layer of each of a plurality of odd numberth metal electrolytic foils and to be withdrawn to another side of the main electrode layer of each of a plurality of even numberth metal electrolytic foils among the plurality of first to nth metal electrolytic foils. [Claim 17] The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the molding member molds the plurality of first to nth metal electrolytic foils in either a planar shape or a cylindrical shape, and in the case of molding the plurality of first to the nth metal electrolytic foils in the cylindrical shape, winds and molds the plurality of first to the nth metal electrolytic foils. [Claim 18] A method of manufacturing a nonpolar metal electrolytic capacitor, the method comprising: an etching process of arranging a plurality of grooves on both surfaces of a metal foil by using a direct current (DC) etching method; a forming process of forming a metal oxide film on the metal foil by using an anodic oxidation method when the plurality of grooves is formed on the metal foil; a process of forming a seed electrode layer to be penetrated into the metal oxide film by using a chemical vapor deposition (CVD) method when the metal oxide film is formed; a process of forming a main electrode layer to fill the plurality of grooves formed on the metal foil via the seed electrode layer as a medium by using a plating method when the seed electrode layer is formed; a process of forming a lead terminal on the main electrode layer when the main electrode layer is formed; and a molding process of sealing the metal foil so that the lead terminal is externally protruded when the lead terminal is formed. [Claim 19] The method of claim 18, wherein the material of the metal foil formed in the etching process uses aluminum (Al). [Claim 20] The method of claim 18, wherein the material of the metal oxide film formed in the forming process includes alumina (A1203). [Claim 21] The method of claim 18, wherein the process of forming the seed electrode layer forms the seed electrode layer by using a thermal evaporation method or a molecular layer growth method. [Claim 22] The method of claim 18, wherein, in the process of forming the seed electrode layer, the material of the seed electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 23] The method of claim 18, wherein the process of forming the main electrode layer forms the main electrode layer by using an electrolytic plating method [Claim 24] The method of claim 18, wherein, in the process of forming the main electrode layer, the material of the main electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 25] The method of claim 18, wherein, when the main electrode layer is formed to improve an adhesive strength of the lead terminal in the process of forming the main electrode layer, a process of forming a conductive adhesive layer is further provided, and the conductive adhesive layer uses solder paste, electroless plating or electrolytic plating. [Claim 26] The method of claim 18, wherein the molding process molds the metal foil, including the main electrode layer, in either a planar shape or a cylindrical shape when the main electrode layer is formed, and in the case of molding the metal foil in the cylindrical shape, winds and molds the metal foil. [Claim 27] A method of manufacturing a nonpolar multi-layer metal electrolytic capacitor, the method comprising: an etching process of arranging a plurality of grooves on both surfaces of a metal foil by using a direct current (DC) etching method; a forming process of forming a metal oxide film on the metal foil by using an anodic oxidation method when the plurality of grooves is formed on the metal foil; a process of forming a seed electrode layer to be penetrated into the metal oxide film by using a chemical vapor deposition (CVD) method when the metal oxide film is formed; a process of forming a main electrode layer to fill the plurality of grooves formed on the metal foil via the seed electrode layer as a medium by using a plating method when the seed electrode layer is formed; a process of forming a plurality of first to nth metal electrolytic foils by cutting the metal foil when the main electrode layer is formed; a process of forming a metal electrolytic foil multi-layer body by pressing the plurality of first to nth metal electrolytic foils with a high pressure when the plurality of first to nth metal electrolytic foils is formed; a process of forming a lead terminal on the main electrode layer, which is located in an outer portion of the first metal electrolytic foil and the nth metal electrolytic foil amount the metal electrolytic foil multi-layer body when the metal electrolytic foil multi-layer body is formed; and a molding process of sealing the metal electrolytic foil multi-layer body so that the lead terminal is externally protruded when the lead terminal is formed. [Claim 28] The method of claim 27, wherein each of the plurality of the first to the nth metal electrolytic foils uses aluminum (Al). [Claim 29] The method of claim 27, wherein the plurality of the first to the nth metal electrolytic foils formed in the process of forming the plurality of the first to the nth metal electrolytic foils is formed by repeating the etching process through the process of forming the main electrode layer, or formed by using the plurality of metal electrolytic foils, which is formed by cutting the metal foil including the main electrode layer, or the plurality of metal electrolytic foils, which is formed by repeating the etching process through the process of forming the main electrode layer. [Claim 30] The method of claim 27, wherein the material of the metal oxide film formed in the formation process includes alumina (A1203). [Claim 31] The method of claim 27, wherein, in the process of forming the seed electrode layer, the material of the seed electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 32] The method of claim 27, wherein, in the process of forming the main electrode layer, the main electrode layer may be formed by using electrolytic plating. [Claim 33] The method of claim 27, wherein, in the process of forming the main electrode layer, the material of the main electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 34] The method of claim 27, wherein the process of forming the main electrode layer further comprises a process of forming a conductive adhesive layer on the main electrode layer to improve an adhesive strength when preparing a multi-layer of the lead terminal and the plurality of the first to the nth metal electrolytic foils, and the conductive adhesive layer uses solder paste, electroless plating or electrolytic plating. [Claim 35] The method of claim 27, wherein, in the process of forming the lead terminal, the lead terminal is formed to be withdrawn to one side of the main electrode layer of each of a plurality of odd numberth metal electrolytic foils and to be withdrawn to another side of the main electrode layer of each of a plurality of even numberth metal electrolytic foils among the plurality of first to nth metal electrolytic foils. [Claim 36] The method of claim 27, wherein the molding process molds the plurality of first to the n11' metal electrolytic foils in either a planar shape or a cylindrical shape, and in the case of molding the plurality of first to the nth metal electrolytic foils in the cylindrical shape, winds and molds the plurality of first to the nth metal electrolytic foils. [Claim 37] Metal electrolytic capacitor and method manufacturing thereof as claimed substantially as herein described with forgoing description & drawings. [ABSTRACT] A nonpolar metal electrolytic capacitor in which an electric conductivity is significantly improved by applying a metal material, instead of a solid electrolyte and electrolyte of an aluminum electrolytic capacitor, and a manufacturing method thereof is provided. A nonpolar metal electrolytic capacitor 10 includes a metal foil 11 including a plurality of grooveslla arranged on both surfaces of the metal foil 11, a metal oxide film l2 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a, a lead terminal 15 being installed in the main electrode layer 14, and a molding member 16 being provided so that the lead terminal 15 is externally protruded from the molding member 16, and the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14 are sealed.

Full Text

FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. Metal Electrolytic Capacitor and method manufacturing thereof
2.
(A) OH, Young Joo
(B) Korea.
(C) 201ho,Doosan Villa
(D) 116-2 Cheongdam-dong Gangnam-gu Seoul 135-100
Republic of Korea
The following specification particularly describes the invention and the manner in which it is to be performed.

[Technical Field]
The present invention relates to a nonpolar metal electrolytic capacitor in which an electric conductivity is significantly improved by applying a metal material, instead of a solid electrolyte and electrolyte of an aluminum electrolytic capacitor, and a manufacturing method thereof.
[Background Art]
An aluminum electrolytic capacitor is used for a flow frequency bypass or
a smoothing circuit of a power source. Hereinafter, a method of manufacturing
the aluminum electrolytic capacitor will be briefly described.
An etching process on an aluminum foil is performed to enlarge a surface area of
the aluminum foil and thereby increase an electric capacity. When the etching
process is completed, a forming process of forming a dielectric substance on the
aluminum foil is performed whereby cathode and anode aluminum foils are
manufactured to be used for assembly of the aluminum electrolytic capacitor. When
the etching process and the forming process are completed, a slitting process of
cutting the completed aluminum foil and a separator by as long as a desired width
based on the length of a product is performed. When the slitting process is
completed, a stitching process of stitching an aluminum lead patch, which is a
lead terminal, to the aluminum foil is performed.
When the slitting of the aluminum foil and the separator is completed, a winding
process of disposing the separator between the anode aluminum foil and the cathode
aluminum foil, and then winding the separator and the aluminum foils in a
cylindrical shape and attaching a tape thereto, so as to not be unwounded. When
the winding process is completed, an impregnation and curling process of disposing
the wound device into an aluminum case, injecting an electrolyte, and curling the
aluminum and a sealing material is performed. When the curling process is

completed, an aging process of restoring a damage to the dielectric substance is performed whereby assembly of the aluminum electrolytic capacitor is completed. Due to the current development in digitalization and thinness of electronic devices, when applying the conventional aluminum electrolytic capacitor, there are some problems as follow.
Since the aluminum electrolytic capacitor uses the electrolyte, an electric conductivity is comparatively low and thus there is some constraint on a long life of the aluminum electrolytic capacitor in a high frequency area. Also, there are some constraints on improvement of reliability, a high frequency response, a low equivalent series resistance (ESR), and impedance. Also, due to a comparatively high ripple pyrexia, there are some constraints on stability and environments, such as fuming and firing.
[Disclosure]
[Technical Problem]
The present invention is conceived to solve the above-described problems
and thus provides a nonpolar metal electrolytic capacitor in which an electric
conductivity is improved by about 10,000 to 1,000,000 folds by applying a metal
material for an electrolyte, in comparison to when using a conventional electrolyte
or an organic semiconductor, a nonpolar multi-layer metal electrolytic capacitor
using the same, and a manufacturing method thereof.
The present invention also provides a nonpolar metal electrolytic capacitor which
can improve a thinness, a low equivalent series resistance (ESR), a reduction in
a ripple pyrexia, a long life, a heat-resistant stability, non-fuming, non-firing,
and environment by using a metal material for an electrolyte, a nonpolar
multi-layer metal electrolytic capacitor using the same, and a manufacturing
method thereof.

The present invention also provides a nonpolar metal electrolytic capacitor which can be simply provided in a multi-layer by using a metal material for an electrolyte, which is impossible in a conventional aluminum electrolytic capacitor structure, a nonpolar multi-layer metal electrolytic capacitor using the same, and a manufacturing method thereof. [Technical Solution]
According to an aspect of the present invention, there is provided a nonpolar metal electrolytic capacitor including: a metal foil including a plurality of grooves arranged on both surfaces of the metal foil; a metal oxide film being formed on the plurality of grooves formed on the metal foil; a seed electrode layer being formed on the metal oxide film, and a main electrode layer being formed on the seed electrode layer to fill the plurality of grooves; a lead terminal being installed in the main electrode layer; and a molding member being provided so that the lead terminal is externally protruded from the molding member, and the metal foil, the metal oxide film, the seed electrode layer, and the main electrode layer are sealed.
According to another aspect of the present invention, there is provided a
method of manufacturing a nonpolar metal electrolytic capacitor, the method
including: an etching process of arranging a plurality of grooves on both surfaces
of a metal foil by using a direct current (DC) etching method; a forming process
of forming a metal oxide film on the metal foil by using an anodic oxidation method
when the plurality of grooves is formed on the metal foil; a process of forming
a seed electrode layer to be penetrated into the metal oxide film by using a chemical
vapor deposition (CVD) method when the metal oxide film is formed; a process of
forming a main electrode layer to fill the plurality of grooves formed on the metal
foil via the seed electrode layer as a medium by using a plating method when the

seed electrode layer is formed; a process of forming a lead terminal on the main electrode layer when the main electrode layer is formed; and a molding process of sealing the metal foil so that the lead terminal is externally protruded when the lead terminal is formed. [Advantageous Effects]
As described above, according to the present invention, there is provided a nonpolar metal electrolytic capacitor in which an electric conductivity is improved by about 10,000 to 1,000,000 folds by applying a metal material for an electrolyte, in comparison to when using a conventional electrolyte or an organic semiconductor. In this instance, the nonpolar metal electrolytic capacitor may be provided in a serial multi-layer type and thus may be used in a high voltage. Also, the nonpolar metal electrolytic capacitor is nonpolar and thus has no directivity and has a high stability. Also, it is possible to improve a thinness, a low ESR, a heat-resistant stability, non-fuming, non-firing, and environment Although the present invention has been described in connection with the embodiment of the present invention shown in the accompanying drawings, it is not limited thereto since it will be apparent to those skilled in the art that various substitutions, modifications and changes may be made thereto without departing from the scope and spirits of the invention. [Description of Drawings]
FIG. 1 is a cross-sectional view illustrating a nonpolar metal electrolytic capacitor according to the present invention;
FIG. 2 is a cross-sectional view illustrating a nonpolar multi-layer metal
electrolytic capacitor according to the present invention; and
FIGS. 3A through 3G are cross-sectional views illustrating a method of
manufacturing a nonpolar metal electrolytic capacitor and a nonpolar multi-layer

metal electrolytic capacitor according to the present invention. [Best Mode]
Hereinafter, the first embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a cross-sectional view illustrating a nonpolar metal electrolytic capacitor 10 according to the present invention. As shown in FIG. 1, the nonpolar metal electrolytic capacitor 10 includes a metal foil 11 including a plurality of grooveslla arranged on both surfaces of the metal foil 11, a metal oxide filml2 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a, a lead terminal 15 being installed in the main electrode layer 14, and a molding member 16 being provided so that the lead terminal 15 is externally protruded from the molding member 16, and the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14 are sealed.
A configuration of the nonpolar metal electrolytic capacitor 10 will be further described in detail.
As shown in FIG. 1, the nonpolar metal electrolytic capacitor 10 includes the metal foil 11, the metal oxide film 12, the seed electrode layer 13, the main electrode layer 14, the lead terminal 15, and the molding member 16. Hereinafter, a configuration thereof will be sequentially described.
The plurality of grooves 11a is arranged on the both surfaces of the metal
foil 11 to increase a surface area. In this instance, aluminum (Al) material is
used. Also, each of the plurality of grooves 11a (shown in FIG. 3B) formed on
the metal foil 11 has a width (a, b: shown in 3B) of 0.1 to 5 , and a height
(c: shown in FIG. 3B) of 10 to 100 . The width of the groove 11a may be,

preferably, 1 and the height of the groove 11a may be, preferably, 40
The metal oxide film 12 is formed on the plurality of grooves 11a arranged on the metal foil 11. In this instance, the metal oxide film 12 is formed of alumina (AI2O3). Also, when alumina (A1A) is applied for the metal foil 11, the metal foil 11 is formed by oxidizing the surface alumina (A1203).
The seed electrode layer 13 corresponds to a portion where small cylindrical shapes are arranged, as shown in FIG. 1, and is formed on the metal oxide film 12. In this instance, the seed electrode layer 13 is formed to be penetrated into the metal oxide film 12 by using any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au).
The main electrode layer 14 is formed on the seed electrode layer 13 to fill the plurality of grooves 11a, and uses any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). Also, a conductive adhesive layer 17 is further provided on the main electrode layer 14 before installing the lead terminal 15 in the main electrode layer 14. In this instance, the conductive adhesive layer 17 is formed using a solder paste, electroless plating or electrolytic plating. The conductive adhesive layer 17 is provided to improve an adhesive strength and an adhering process.
The lead terminal 15 is installed in the main electrode layer 14. In FIG. 1, the lead terminal 15 is installed in the conductive adhesive layer 17. However, when the conductive adhesive layer 17 is not provided, the lead terminal 15 is installed in the main electrode layer 14 with a mechanical force using a high pressure.
The molding member 16 uses epoxy molding compound (EMC). In this instance,
when the lead terminal 15 is installed in either the main electrode layer 14 or
the conductive adhesive layer 17, the molding member 16 is provided to seal the

metal foil 11, the metal oxide film 12, the seed electrode layer 13, ad the main electrode layer 14 while the lead terminal 15 is externally protruded. Also, the molding member 16 may be molded in a planar shape as shown in FIG. 1. Also, the molding member 16 may be molding in a cylindrical shape (not shown). When the molding member 16 is molded in the cylindrical shape, the metal foil 11 is molded in a wound state like the conventional aluminum condenser.
Hereinafter, the second embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 2 is a cross-sectional view illustrating a nonpolar multi-layer metal electrolytic capacitor 100 according to the present invention. As shown in FIG. 2, the nonpolar multi-layer metal electrolytic capacitor 100 includes: a plurality of first to nth metal electrolytic foils 10a, 10b, •••, lOn, wherein each of the metal electrolytic foils 10a, 10b, •••, lOn includes a metal foil 11 including a plurality of grooves 11a arranged on both surfaces of the metal foil 11, a metal oxide film 12 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a; a lead terminal 15 being installed in the main electrode layer 14 which is located on an outer portion of each of the first metal electrolytic foil 10a and the nth metal electrolytic foil lOn among the first to the n,h metal electrolytic foil 10a, 10b, •••, lOn; and a molding member 16 being provided so that the lead terminal 15 is externally protruded and the first to the nth metal electrolytic foils 10a, 10b, •••, lOn is sealed.
A configuration of the nonpolar multi-layer metal electrolytic capacitor
100 will be further described in detail.
As shown in FIG. 2, the nonpolar multi-layer metal electrolytic capacitor

100 includes the first to the nl metal electrolytic foils 10a, 10b, •••, lOn, the lead terminal 15, and the molding member 16. Hereinafter, a configuration thereof will be sequentially described.
Each of the first to the nth metal electrolytic foils 10a, 10b, •••, lOn includes the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14. The configuration thereof is the same as the configuration of the nonpolar metal electrolytic capacitor 10 according to the first embodiment and thus will be briefly described.
The plurality of grooves 11a is arranged on the both surfaces of the metal foil 11 and is formed of aluminum (Al). Also, the metal oxide film 12 is formed on the plurality of grooves 11a arranged on the metal foil 11, and is formed of alumina (A1203). Also, the seed electrode layer 13 is formed on the metal oxide film 12, and the main electrode layer 14 is formed on the seed electrode layer
13 to fill the plurality of grooves 11a. In this instance, each of the seed
electrode layer 13 and the main electrode layer 14 uses any one of aluminum (Al),
copper (Cu), zinc (Zn), silver (Ag), and gold (Au). Also, a conductive adhesive
layer 17 is further provided on the main electrode layer 14. Accordingly, when
providing the first to the nth metal electrolytic foils 10a, 10b, •••, lOn in a
multi-layer structure or when installing the lead terminal 15, an adhesive strength
may be improved. The conductive adhesive layer 17 is formed using a solder paste,
electroless plating or electrolytic plating.
The nonpolar multi-layer metal electrolytic capacitor 100 may be formed in a serial multi-layer type to be used for a high-voltage and a low capacity. When providing the nonpolar multi-layer metal electrolytic capacitor 100 in the serial multi-layer type, the lead terminal 15 is installed in the main electrode layer
14 which is located on an outer portion of each of the first metal electrolytic

foil 10a and the nl metal electrolytic foil lOn among the first to the nl metal electrolytic foils 10a, 10b, •••, lOn. In this instance, when the conductive adhesive layer 17 is not provided to the first to the nth metal electrolytic foil 10a, 10b, •••, lOn, the lead terminal 15 is directly installed in the main electrode layer 14. When the conductive adhesive material 17 is provided, the lead terminal 15 is installed in the conductive adhesive layer 17. In this instance, when the conductive adhesive layer 17 is not provided, each of the first to the nth metal electrolytic foil 10a, 10b, •••, lOn is provided in a multi-layer by a mechanical force using a high pressure.
Also, the nonpolar multi-layer metal electrolytic capacitor 100 may be provided in a parallel multi-layer type to be used for a low-voltage and a high capacity. When providing the nonpolar multi-layer metal electrolytic capacitor 100 in the parallel multi-layer type, the lead terminal 15 is installed as shown in FIG. 2 using a dotted line. Specifically, the lead terminal 15 is installed to be withdrawn to one side of the main electrode layer 14 of each of a plurality of odd number th metal electrolytic foils 10a, •••, 10n-l, and to be withdrawn to another side of the main electrode layer 14 of each of a plurality of even number th metal electrolytic foils 10b, •••, lOn among the plurality of first to nth metal electrolytic foils 10a, 10b, •••, lOn.
When the lead terminal 15 is installed in the first to the nth metal
electrolytic foils 10a, 10b, •••, lOn, the molding member 16 is provided. In this
instance, the molding member 16 is provided so that the lead terminal 16 may be
externally protruded, and the first to the nth metal electrolytic foils 10a, 10b,
•••, lOn may be sealed. When sealing the first to the nth metal electrolytic foils
10a, 10b, •••, lOn, the molding member molds the first to the nth metal electrolytic
foils 10a, 10b, •••, lOn in a planar shape or a cylindrical shape (not shown). Also,

in the case of molding the first to the n* metal electrolytic foils 10a, 10b, •••, lOn in the cylindrical shape, the molding member 16 winds and molds the first to the nth metal electrolytic foils 10a, 10b, ••*, lOn.
Hereinafter, a method of manufacturing the nonpolar metal electrolytic capacitor 10 according to the first embodiment and the nonpolar multi-layer metal electrolytic capacitor 100 according to the second embodiment, constructed as above, will be described with reference to the accompanying drawings.
Firstly, a method of manufacturing the nonpolar metal electrolytic capacitor 10 according to the first embodiment will be described with reference to FIGS. 3A through 3F.
As shown in FIGS. 3A and 3B, an etching process of forming a plurality grooves 11a on both surfaces of a metal foil 11, formed of aluminum (Al), by using an electrochemical method, that is, a direct current (DC) etching method is performed to increase a surface area of the metal foil 11. When the plurality of grooves 11a is formed on the metal foil 11, a forming process of forming a metal oxide film 12, formed of alumina (A1203), on the metal foil 11 by using an anodic oxidation method is performed as shown in FIG. 3C. In this instance, the anodic oxidation is performed so that a proper voltage of a capacitor may be 140% to 160% of 6. 3 V to 500V.
As shown in FIGS. 3D and 3E, when the metal oxide film 12 is formed, a process of forming a seed electrode layer to be penetrated into the metal oxide film 12 and thereby grow by using any one of a chemical vapor deposition (CVD) method, a thermal evaporation method, and a molecular layer growth method is performed. In this instance, the molecular growth method uses a metal organic CVD method.
As shown in FIG. 3F, when the seed electrode layer 13 is formed, a process
of forming a main electrode layer 14 to fill the plurality of grooves 11a formed

on the metal foil 11 via the seed electrode layer 13 as a medium by using electroless plating or electrolytic plating (AC: alternative current, DC: direct current) is performed. In this instance, the seed electrode layer 13 or the main electrode layer 14 may use any one of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). Also, when the main electrode layer 14 is formed in the process of forming the main electrode layer 14, a process of forming a conductive adhesive layer 17 on the main electrode layer 14 may be further performed. In this instance, the conductive adhesive layer 17 is provided to improve an adhesive strength and is formed by using a solder paste, electroless plating or electrolytic plating.
As shown in FIG. 1, when the main electrode layer 14 is formed, a process of forming the lead terminal 15 on the main electrode layer 14 is performed. Also, a molding process of sealing the metal foil 11 so that the lead terminal 15 is externally protruded is performed. Through the above process, the nonpolar metal electrolytic capacitor 10 is manufactured. The metal foil 11 may be molded in a planar shape or a cylindrical shape in the molding process.
Hereinafter, a method of manufacturing the nonpolar multi-layer metal electrolytic capacitor 100 according to the second embodiment will be described.
In the method of manufacturing the nonpolar multi-layer metal electrolytic
capacitor 100, an etching process of forming a plurality grooves 11a on both
surfaces of a metal foil 11, formed of aluminum (Al), by using a direct current
(DC) etching method through a process of forming a main electrode layer 14 to fill
the plurality of grooves 11a formed on the metal foil 11 via the seed electrode
layer 13 as a medium are the same as the manufacturing process of the nonpolar
metal electrolytic capacitor according to the first embodiment, and thus will be
omitted here.
When the main electrode layer 14 is formed through the processes as shown

in FIGS. 3A through 3F, a process of forming first to n metal electrolytic foils 10a, 10b, •••, lOn by cutting the metal foil 11 formed on the main electrode layer 14. As shown in FIG. 3G, when the first to the nth metal electrolytic foils 10a, 10b, •••, lOn are formed, a process of forming a metal electrolytic foil multi-layer body 100a by pressing first to the nth metal electrolytic foils 10a, 10b, •••, lOn with a high pressure is performed.
When forming the metal electrolytic foil multi-layer body 100a, the plurality of the first to the nth metal electrolytic foils 10a, 10b, •••, lOn may be formed by repeating the etching process through the process of forming the main electrode layer 14, or formed by using the plurality of metal electrolytic foils 10a, 10b, •••, lOn, which is formed by cutting the metal foil 11 including the main electrode layer 14, or the plurality of metal electrolytic foils 10a, 10b, •••, lOn, which is formed by repeating the etching process through the process of forming the main electrode layer 14.
When the metal electrolytic foil multi-layer body 100a is formed, a process of forming the lead terminal 15, as shown in FIG. 15, on the main electrode layer 14, which is located on an outer portion of each of the first metal electrolytic foil 10a and the nth metal electrolytic foil lOn of the metal electrolytic foil multi-layer body 100a, is performed. When forming the lead terminal on the main electrode layer 14 which is located on the outer portion of the first metal electrolytic foil 10a and the nth metal electrolytic foil lOn, it is possible to use the nonpolar multi-layer metal electrolytic capacitor 100, which is in the serial multi-layer shape, for a high-voltage and a small capacity.
Also, when using the nonpolar multi-layer metal electrolytic capacitor 100
for a low voltage and a high capacity, the lead terminal 15, in the process of
forming the lead terminal 15, is formed to be withdrawn to one side of the main

electrode layer 14 of each of a plurality of odd numberth metal electrolytic foils and 10a, •••, 10n-l, to be withdrawn to another side of the main electrode layer 14 of each of a plurality of even numberth metal electrolytic foils 10b, •••, lOn, among the plurality of first to nth metal electrolytic foils 10a, 10b, •••, lOn, in order to provide the nonpolar multi-layer metal electrolytic capacitor 100 in a parallel multi-layer type.
When providing the first to the nth metal electrolytic foils 10a, 10b, •••, lOn in either the serial multi-layer type or the parallel multi-layer type, it is possible to improve an adhesive strength and an adhering process between the lead terminal 15 and the first to the nth metal electrolytic foils 10a, 10b, •••, lOn by using the conductive adhesive layer 17, which is the same as the method of manufacturing the nonpolar metal electrolytic capacitor 10. In this instance, the conductive adhesive layer 17 is formed using a solder paste, electroless plating or electrolytic plating. When the conductive adhesive layer 17 is not provided, the first to the nth metal electrolytic foils 10a, 10b, •••, lOn are pressed by a mechanical force using a high pressure and thereby provided in a multi-layer.
When the first to the nth metal electrolytic foils 10a, 10b, •••, lOn are
provided in the serial multi-layer type or the parallel multi-layer type by the
mechanical force or the conductive adhesive layer 17, a molding process of sealing
the metal electrolytic foil multi-layer body 100a so that the lead terminal 15
is externally protruded is performed. Through the above process, the
manufacturing process of the nonpolar multi-layer metal electrolytic capacitor
100 is completed. When molding the first to the nth metal electrolytic foils 10a,
10b, •••, lOn during the molding process, the first to the nth metal electrolytic
foils 10a, 10b, •••, lOn may be molded in a planar shape or a cylindrical shape.
[Industrial Applicability]

The present invention may be applied to a nonpolar metal electrolytic capacitor in which an electric conductivity is improved by about 10,000 to 1,000,000 folds by applying a metal material for an electrolyte, in comparison to when using a conventional electrolyte or an organic semiconductor, a nonpolar multi-layer metal electrolytic capacitor using the same, and a manufacturing method thereof.

I Claim: [Claim 1]
A nonpolar metal electrolytic capacitor comprising:
a metal foil including a plurality of grooves arranged on both surfaces of the metal foil;
a metal oxide film being formed on the plurality of grooves formed on the metal foil;
a seed electrode layer being formed on the metal oxide film, and a main electrode layer being formed on the seed electrode layer to fill the plurality of grooves;
a lead terminal being installed in the main electrode layer; and
a molding member being provided so that the lead terminal is externally protruded from the molding member, and the metal foil, the metal oxide film, the seed electrode layer, and the main electrode layer are sealed. [Claim 2]
The nonpolar metal electrolytic capacitor of claim 1, wherein each of the plurality of grooves formed on the metal foil has a width of about 0. 1 to about 5 . [Claim 3]
The nonpolar metal electrolytic capacitor of claim 1, wherein each of the plurality of grooves formed on the metal foil has a height of about 10 to about 100 . [Claim 4]
The nonpolar metal electrolytic capacitor of claim 1, wherein the metal foil
is made of aluminum (Al).
[Claim 5]

The nonpolar metal electrolytic capacitor of claim 1, wherein the metal
oxide film includes alumina (A1203).
[Claim 6]
The nonpolar metal electrolytic capacitor of claim 1, wherein the seed
electrode layer uses any one of selected from the group consisting of aluminum
(Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au).
[Claim 7]
The nonpolar metal electrolytic capacitor of claim 1, wherein the main
electrode layer uses any one of selected from the group consisting of aluminum
(Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au).
[Claim 8]
The nonpolar metal electrolytic capacitor of claim 1, wherein the main
electrode layer further comprises a conductive adhesive layer.
[Claim 9]
The nonpolar metal electrolytic capacitor of claim 1, wherein the molding
member molds the metal foil, including the main electrode layer, into either a
planar shape or a cylindrical shape, and in the case of molding the metal foil
in the cylindrical shape, winds and molds the metal foil.
[Claim 10]
A nonpolar multi-layer metal electrolytic capacitor comprising:
a plurality of first to nth metal electrolytic foils, wherein each of the
metal electrolytic foils comprises a metal foil including a plurality of grooves
arranged on both surfaces of the metal foil, a metal oxide film being formed on
the plurality of grooves formed on the metal foil, a seed electrode layer being
formed on the metal oxide film, and a main electrode layer being formed on the
seed electrode layer to fill the plurality of grooves;

a lead terminal being installed in the main electrode layer which is located
on an outer portion of each of the first metal electrolytic foil and the nth metal
electrolytic foil among the first to the nth metal electrolytic foil; and
a molding member being provided so that the lead terminal is externally
protruded and the first to the nth metal electrolytic foils is sealed.
[Claim 11]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein
the metal oxide film of each of the first to the nth metal electrolytic foils is
made of aluminum (Al).
[Claim 12]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein
the metal oxide film of each of the first to the nth metal electrolytic foils includes
alumina (A1203).
[Claim 13]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein
the seed electrode layer of each of the first to the nth metal electrolytic foils
uses any one of selected from the group consisting of aluminum (Al), copper (Cu),
zinc (Zn), silver (Ag), and gold (Au).
[Claim 14]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein
the main electrode layer of each of the first to the nth metal electrolytic foils
uses any one of selected from the group consisting of aluminum (Al), copper (Cu),
zinc (Zn), silver (Ag), and gold (Au).
[Claim 15]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein
a conductive adhesive layer is further disposed between the plurality of first

to n" metal electrolytic foils. [Claim 16]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the lead terminal is installed to be withdrawn to one side of the main electrode layer of each of a plurality of odd numberth metal electrolytic foils and to be withdrawn to another side of the main electrode layer of each of a plurality of even numberth metal electrolytic foils among the plurality of first to nth metal electrolytic foils. [Claim 17]
The nonpolar multi-layer metal electrolytic capacitor of claim 10, wherein the molding member molds the plurality of first to nth metal electrolytic foils in either a planar shape or a cylindrical shape, and in the case of molding the plurality of first to the nth metal electrolytic foils in the cylindrical shape, winds and molds the plurality of first to the nth metal electrolytic foils. [Claim 18]
A method of manufacturing a nonpolar metal electrolytic capacitor, the method comprising:
an etching process of arranging a plurality of grooves on both surfaces of a metal foil by using a direct current (DC) etching method;
a forming process of forming a metal oxide film on the metal foil by using an anodic oxidation method when the plurality of grooves is formed on the metal foil;
a process of forming a seed electrode layer to be penetrated into the metal
oxide film by using a chemical vapor deposition (CVD) method when the metal oxide
film is formed;
a process of forming a main electrode layer to fill the plurality of grooves

formed on the metal foil via the seed electrode layer as a medium by using a plating method when the seed electrode layer is formed;
a process of forming a lead terminal on the main electrode layer when the main electrode layer is formed; and
a molding process of sealing the metal foil so that the lead terminal is externally protruded when the lead terminal is formed. [Claim 19]
The method of claim 18, wherein the material of the metal foil formed in the etching process uses aluminum (Al). [Claim 20]
The method of claim 18, wherein the material of the metal oxide film formed in the forming process includes alumina (A1203). [Claim 21]
The method of claim 18, wherein the process of forming the seed electrode layer forms the seed electrode layer by using a thermal evaporation method or a molecular layer growth method. [Claim 22]
The method of claim 18, wherein, in the process of forming the seed electrode layer, the material of the seed electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au).
[Claim 23]
The method of claim 18, wherein the process of forming the main electrode
layer forms the main electrode layer by using an electrolytic plating method
[Claim 24]

The method of claim 18, wherein, in the process of forming the main electrode layer, the material of the main electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 25]
The method of claim 18, wherein, when the main electrode layer is formed to improve an adhesive strength of the lead terminal in the process of forming the main electrode layer, a process of forming a conductive adhesive layer is further provided, and the conductive adhesive layer uses solder paste, electroless plating or electrolytic plating. [Claim 26]
The method of claim 18, wherein the molding process molds the metal foil, including the main electrode layer, in either a planar shape or a cylindrical shape when the main electrode layer is formed, and in the case of molding the metal foil in the cylindrical shape, winds and molds the metal foil. [Claim 27]
A method of manufacturing a nonpolar multi-layer metal electrolytic capacitor, the method comprising:
an etching process of arranging a plurality of grooves on both surfaces of a metal foil by using a direct current (DC) etching method;
a forming process of forming a metal oxide film on the metal foil by using an anodic oxidation method when the plurality of grooves is formed on the metal foil;
a process of forming a seed electrode layer to be penetrated into the metal
oxide film by using a chemical vapor deposition (CVD) method when the metal oxide
film is formed;

a process of forming a main electrode layer to fill the plurality of grooves formed on the metal foil via the seed electrode layer as a medium by using a plating method when the seed electrode layer is formed;
a process of forming a plurality of first to nth metal electrolytic foils by cutting the metal foil when the main electrode layer is formed;
a process of forming a metal electrolytic foil multi-layer body by pressing the plurality of first to nth metal electrolytic foils with a high pressure when the plurality of first to nth metal electrolytic foils is formed;
a process of forming a lead terminal on the main electrode layer, which is located in an outer portion of the first metal electrolytic foil and the nth metal electrolytic foil amount the metal electrolytic foil multi-layer body when the metal electrolytic foil multi-layer body is formed; and
a molding process of sealing the metal electrolytic foil multi-layer body so that the lead terminal is externally protruded when the lead terminal is formed. [Claim 28]
The method of claim 27, wherein each of the plurality of the first to the nth metal electrolytic foils uses aluminum (Al). [Claim 29]
The method of claim 27, wherein the plurality of the first to the nth metal
electrolytic foils formed in the process of forming the plurality of the first
to the nth metal electrolytic foils is formed by repeating the etching process
through the process of forming the main electrode layer, or formed by using the
plurality of metal electrolytic foils, which is formed by cutting the metal foil
including the main electrode layer, or the plurality of metal electrolytic foils,
which is formed by repeating the etching process through the process of forming
the main electrode layer.

[Claim 30]
The method of claim 27, wherein the material of the metal oxide film formed in the formation process includes alumina (A1203). [Claim 31]
The method of claim 27, wherein, in the process of forming the seed electrode layer, the material of the seed electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 32]
The method of claim 27, wherein, in the process of forming the main electrode layer, the main electrode layer may be formed by using electrolytic plating. [Claim 33]
The method of claim 27, wherein, in the process of forming the main electrode layer, the material of the main electrode layer uses any one of selected from the group consisting of aluminum (Al), copper (Cu), zinc (Zn), silver (Ag), and gold (Au). [Claim 34]
The method of claim 27, wherein the process of forming the main electrode layer further comprises a process of forming a conductive adhesive layer on the main electrode layer to improve an adhesive strength when preparing a multi-layer of the lead terminal and the plurality of the first to the nth metal electrolytic foils, and the conductive adhesive layer uses solder paste, electroless plating or electrolytic plating. [Claim 35]
The method of claim 27, wherein, in the process of forming the lead terminal,
the lead terminal is formed to be withdrawn to one side of the main electrode layer

of each of a plurality of odd numberth metal electrolytic foils and to be withdrawn to another side of the main electrode layer of each of a plurality of even numberth metal electrolytic foils among the plurality of first to nth metal electrolytic foils.
[Claim 36]
The method of claim 27, wherein the molding process molds the plurality of first to the n11' metal electrolytic foils in either a planar shape or a cylindrical shape, and in the case of molding the plurality of first to the nth metal electrolytic foils in the cylindrical shape, winds and molds the plurality of first to the nth metal electrolytic foils.
[Claim 37]
Metal electrolytic capacitor and method manufacturing thereof as claimed substantially as herein described with forgoing description & drawings.

[ABSTRACT]
A nonpolar metal electrolytic capacitor in which an electric conductivity is significantly improved by applying a metal material, instead of a solid electrolyte and electrolyte of an aluminum electrolytic capacitor, and a manufacturing method thereof is provided. A nonpolar metal electrolytic capacitor 10 includes a metal foil 11 including a plurality of grooveslla arranged on both surfaces of the metal foil 11, a metal oxide film l2 being formed on the plurality of grooves 11a formed on the metal foil 11, a seed electrode layer 13 being formed on the metal oxide film 12, and a main electrode layer 14 being formed on the seed electrode layer 13 to fill the plurality of grooves 11a, a lead terminal 15 being installed in the main electrode layer 14, and a molding member 16 being provided so that the lead terminal 15 is externally protruded from the molding member 16, and the metal foil 11, the metal oxide film 12, the seed electrode layer 13, and the main electrode layer 14 are sealed.

Documents:

661-MUMNP-2008-ABSTRACT(25-6-2013).pdf

661-mumnp-2008-abstract.doc

661-mumnp-2008-abstract.pdf

661-MUMNP-2008-CLAIMS(AMENDED)-(25-6-2013).pdf

661-mumnp-2008-claims.doc

661-mumnp-2008-claims.pdf

661-MUMNP-2008-CORRESPONDENCE 10-6-2008.pdf

661-MUMNP-2008-CORRESPONDENCE 16-6-2008.pdf

661-MUMNP-2008-CORRESPONDENCE(12-7-2013).pdf

661-MUMNP-2008-CORRESPONDENCE(7-2-2011).pdf

661-mumnp-2008-correspondence-received.pdf

661-mumnp-2008-description (complete).pdf

661-MUMNP-2008-DRAWING(25-6-2013).pdf

661-mumnp-2008-drawings.pdf

661-MUMNP-2008-ENGLISH TRANSLATION(12-7-2013).pdf

661-MUMNP-2008-FORM 1 16-6-2008.pdf

661-MUMNP-2008-FORM 1(12-2-2014).pdf

661-MUMNP-2008-FORM 1(25-6-2013).pdf

661-MUMNP-2008-FORM 18 10-6-2008.pdf

661-MUMNP-2008-FORM 2(TITLE PAGE)-(12-2-2014).pdf

661-MUMNP-2008-FORM 2(TITLE PAGE)-(25-6-2013).pdf

661-MUMNP-2008-FORM 2(TITLE PAGE)-(7-4-2008).pdf

661-MUMNP-2008-FORM 26(25-6-2013).pdf

661-MUMNP-2008-FORM 3(16-6-2008).pdf

661-MUMNP-2008-FORM 3(25-6-2013).pdf

661-mumnp-2008-form-1.pdf

661-mumnp-2008-form-2.doc

661-mumnp-2008-form-2.pdf

661-mumnp-2008-form-3.pdf

661-mumnp-2008-form-5.pdf

661-MUMNP-2008-MARKED COPY(25-6-2013).pdf

661-MUMNP-2008-OTHER DOCUMENT(25-6-2013).pdf

661-MUMNP-2008-REPLY TO EXAMINATION REPORT(25-6-2013).pdf

661-MUMNP-2008-REPLY TO HEARING(12-2-2014).pdf

661-MUMNP-2008-SPECIFICATION(AMENDED)-(25-6-2013).pdf

661.-MUMNP-2008-FORM 3 16-6-2008.pdf

661.-MUMNP-2008-FORM 5 16-6-2008.pdf

661.-MUMNP-2008-POWER OF ATTORNEY 16-6-2008.pdf

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Patent Number

259205

Indian Patent Application Number

661/MUMNP/2008

PG Journal Number

10/2014

Publication Date

07-Mar-2014

Grant Date

03-Mar-2014

Date of Filing

07-Apr-2008

Name of Patentee

OH YOUNG JOO

Applicant Address

201 HO, DOOSAN VILLA, 116-2 CHEONGDAM-DONG, GANGNAM-GU SEOUL 135-100

Inventors:

#	Inventor's Name	Inventor's Address
1	OH, YOUNG, JOO	201 HO, DOOSAN VILLA 116-2 CHEONGDAM-DONG GANGNAM-GU SEOUL 135-100

PCT International Classification Number

H01G9/00

PCT International Application Number

PCT/KR2007/001995

PCT International Filing date

2007-04-24

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	10-2007-0012342	2007-02-06	Republic of Korea