Electrode Holder with Porous Support for Aluminum Capacitor Formation
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Solution Overview
Problem
Aluminum electrodes with porous layers thicker than 200 micrometers tend to exfoliate during chemical formation in aluminum electrolytic capacitor production, especially when the thickness exceeds 500 micrometers.
Innovation Solution
An electrode holder with insulating support plates and a porous member that contacts the porous layer, allowing chemical formation solution to pass through and preventing deformation and exfoliation by distributing the growth force across multiple positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the porous layer thickness is increased to 200 micrometers or greater, then the electrostatic capacitance is improved, but the porous layer tends to exfoliate during chemical formation
Solution Approach 1:
The support plate is formed with a porous member that has pores allowing chemical formation solution to pass through. This porous structure enables the support plate to provide mechanical support to the thick porous layer while simultaneously allowing the chemical formation solution to reach and treat the porous layer uniformly, preventing exfoliation during the chemical formation process.
Solution Approach 2:
The porous support plate acts as an intermediary between the chemical formation solution and the thick porous layer. It mechanically supports the porous layer from the substrate side, distributing the stress and preventing deformation that would lead to exfoliation, while its porous structure ensures the solution can penetrate through to treat the porous layer effectively.
2Quantity of substance
If the porous layer thickness is increased to maintain capacitance, then the chemical formation film growth causes deformation and exfoliation
Solution Approach 1:
The support plate incorporates a porous member with controlled pore structure that allows chemical formation solution to pass through while providing mechanical support. This dual functionality enables the support plate to maintain the porous layer's structural integrity during chemical formation film growth, preventing deformation and exfoliation even when the porous layer thickness is 200 micrometers or greater.
Solution Approach 2:
The support plate is formed as a composite structure combining insulating material with a porous member. This composite construction provides both the mechanical strength needed to support thick porous layers and the porous characteristics needed to allow solution penetration, thereby maintaining porous layer stability during chemical formation.
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
Prevents exfoliation of porous layers during chemical formation, even when they exceed 200 micrometers in thickness, ensuring stable film growth and maintaining electrostatic capacitance.
Implementation Method 1
the chemical formation solution or the like can pass through this porous member
Data Source
AI summary
An electrode holder and a method for producing an electrode for an aluminum electrolytic capacitor are provided that enable prevention of exfoliation of a porous layer during chemical formation even when the porous layer is formed on an aluminum electrode so as to have a thickness of 200 micrometers or greater. When an aluminum electrode 10 having at least one surface 11 on which a porous layer 17 having a thickness of 200 micrometers or greater is formed is subjected to chemical formation in a chemical formation solution, the aluminum electrode 10 is held by an electrode holder 50. The electrode holder 50 includes: an insulating first support plate 51 configured to overlap the one surface 11 of the aluminum electrode 10; an insulating second support plate 52 configured to overlap the other surface 12 of the aluminum electrode 10; and a connecting part 53 configured to connect the first support plate 51 and the second support plate 52 to each other. A portion of the first support plate 51 that overlaps the porous layer 17 while being in contact therewith is formed with a porous member 510.