Aluminum Capacitor Electrode Material With Fe-Controlled Porous Sintering
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Solution Overview
Problem
Aluminum electrolytic capacitors require higher capacitance and lower equivalent series resistance (ESR) to enhance charging and discharging efficiency, but existing electrode materials face challenges in achieving sufficient surface area and pore connectivity due to excessive sintering, leading to isolated pores and increased ESR.
Innovation Solution
Incorporating an aluminum alloy powder with controlled iron (Fe) content (2-499 mass ppm) into the sintered body on an aluminum foil substrate, allowing for controlled sintering speed and surface area expansion, while maintaining a three-dimensional network structure to reduce ESR and increase capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the thickness of the sintered layer is increased to achieve larger surface area, then the surface area increases, but excessive sintering occurs causing powder particles to sinter too much, making space between particles narrow and pores isolated, thus reducing surface area and capacitance per volume
Solution Approach 1:
The invention changes the chemical composition parameter by controlling Fe content in aluminum alloy powder to 2-499 mass ppm. This parameter change controls the sintering speed and sintering degree, allowing the sintered layer to maintain adequate pore connectivity and surface area for high capacitance per volume.
Solution Approach 2:
The invention uses aluminum alloy powder containing Fe as a composite material component. The Fe-containing aluminum alloy powder creates a specific sintering behavior that produces a porous structure with good connectivity, achieving both high surface area and maintained pore accessibility.
2Ease of manufacture
If conventional electrode materials are used, then manufacturing is straightforward, but equivalent series resistance (ESR) is high, lowering charging and discharging efficiency
Solution Approach 1:
The invention changes the chemical composition parameter by controlling Fe content in aluminum alloy powder to 2-499 mass ppm. This parameter change controls the sintering speed and sintering degree, allowing the sintered layer to maintain adequate pore connectivity and surface area for high capacitance per volume.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach results in an electrode material with improved capacitance and reduced ESR, enhancing the charging and discharging efficiency of aluminum electrolytic capacitors and producing a product of high added value.
Implementation Method 1
sintering of powder forming a sintered body and a substrate, and sintering of powder particles
Implementation Method 2
when the surface is subjected to anodization, an oxide film is formed, and the film functions as a dielectric
Data Source
AI summary
The present invention provides an electrode material for aluminum electrolytic capacitors, the electrode material being capable of exhibiting a high capacitance required for capacitors and having suppressed equivalent series resistance (ESR), and provides a method for producing the electrode material.The present invention provides an electrode material for aluminum electrolytic capacitors, comprising a sintered body of an aluminum alloy powder on at least one surface of a substrate, wherein the substrate is an aluminum foil substrate or an aluminum alloy foil substrate, and the aluminum alloy powder contains Fe in an amount of 2 to 499 mass ppm.