Method of producing a capacitor
View Patent ↗A method of making an electrolytic capacitor includes providing a first electrode that includes a metal substrate, a carbide layer, and a carbonaceous material. The metal substrate includes a metal selected from the group consisting of titanium, aluminum, tantalum, niobium, zirconium, silver, steel, and alloys and combinations thereof. The method further includes providing a second electrode and an electrolyte.
1. A method of making an electrolytic capacitor comprising:
providing a first electrode comprising a metal substrate, a carbide layer, and a carbonaceous material that includes activated carbon, the metal substrate comprising a metal selected from the group consisting of titanium, aluminum, tantalum, niobium, zirconium, silver, steel, and alloys and combinations thereof;
providing a second electrode; and
providing an electrolyte.
2. The method of claim 1 , further comprising roughening a surface of the substrate.
3. The method of claim 2 , wherein the roughening step utilizes at least one process selected from the group consisting of grit blasting and etching.
4. The method of claim 2 , wherein the roughness of the surface as measured by the distance between peaks and valleys at the surface is between approximately 2 and 5 micrometers.
5. The method of claim 1 , further comprising providing a material comprising carbon adjacent the substrate and subjecting the material comprising carbon to a temperature of between approximately 800 and 1000 degrees Celsius to form the carbide layer.
6. The method of claim 5 , wherein the step of providing a material comprising carbon adjacent the substrate comprises depositing the material comprising carbon on the substrate.
7. The method of claim 5 , wherein the material comprising carbon comprises graphite.
8. The method of claim 1 , wherein the step of providing a first electrode comprises providing the carbonaceous material adjacent the carbide layer and heating the carbonaceous material in an oxygen-containing atmosphere to activate at least a portion of the carbonaceous material to form the activated carbon.
9. The method of claim 8 , further comprising introducing an oxide of manganese into the carbonaceous material.
10. The method of claim 9 , wherein the step of introducing an oxide of manganese into the carbonaceous material comprises providing a solution comprising manganese nitrate and heating the solution and the carbonaceous material to form the oxide of manganese.
11. The method of claim 8 , wherein the step of heating the carbonaceous material in an oxygen-containing atmosphere to activate at least a portion of the carbonaceous material comprises heating the carbonaceous material to a temperature of between approximately 300 and 500 degrees Celsius for a period of between approximately 30 and 90 minutes.
12. The method of claim 8 , wherein the step of heating the carbonaceous material in an oxygen-containing atmosphere produces a carbonaceous layer having a layer of the activated carbon and a layer of non-activated carbon.
13. The method of claim 1 , wherein the substrate comprises titanium.
14. The method of claim 1 , wherein the substrate comprises aluminum.
15. The method of claim 1 , further comprising forming a native oxide layer on the substrate.
16. The method of claim 1 , wherein the carbide layer comprises a metal carbide.
17. A method of making an electrolytic capacitor comprising:
preparing a first electrode by providing a carbide layer and a carbonaceous layer on a metal substrate, the carbonaceous layer comprising activated carbon and the metal substrate comprising a metal selected from the group consisting of titanium, aluminum, tantalum, niobium, zirconium, silver, and steel, and alloys and combinations thereof; and
providing the first electrode in a housing along with a second electrode and an electrolyte.
18. The method of claim 17 , further comprising roughening a surface of the substrate such that the roughness of the surface as measured by the distance between peaks and valleys at the surface is between approximately 2 and 5 micrometers.
19. The method of claim 17 , further comprising providing a carbon-containing material adjacent the substrate and subjecting the carbon-containing material to a temperature of between approximately 800 and 1000 degrees Celsius to form the carbide layer.
20. The method of claim 17 , wherein the carbonaceous layer includes both activated and non-activated carbon.
21. The method of claim 17 , further comprising introducing an oxide of manganese into the carbonaceous layer.
22. The method of claim 21 , wherein the step of introducing an oxide of manganese into the carbonaceous layer comprises providing a solution comprising manganese nitrate and heating the solution and the carbonaceous layer to form the oxide of manganese.
23. The method of claim 17 , wherein the substrate comprises a metal selected from the group consisting of titanium and aluminum.
24. The method of claim 17 , wherein the carbide layer comprises a metal carbide.
25. A method of making an electrolytic capacitor comprising:
providing a first layer of material and a second layer of material on a substrate to form a first electrode, the first layer of material comprising a carbide and the second layer of material comprising a carbonaceous material, the substrate formed from a metal selected from the group consisting of titanium, aluminum, tantalum, niobium, zirconium, silver, and steel, and alloys and combinations thereof;
providing the first electrode in a housing;
providing a second electrode in the housing; and
providing an electrolyte in the housing.
26. The method of claim 25 , further comprising roughening a surface of the substrate using a process selected from the group consisting of grit blasting and etching.
27. The method of claim 26 , wherein the roughness of the surface is between approximately 2 and 5 micrometers.
28. The method of claim 25 , further comprising providing graphite adjacent the substrate and subjecting the graphite to a temperature of between approximately 800 and 1000 degrees Celsius to form the first layer.
29. The method of claim 28 , wherein the graphite is provided as a suspension of graphite powder in alcohol.
30. The method of claim 25 , wherein the step of providing the second layer of material comprises heating the carbonaceous material in an oxygen-containing atmosphere to activate at least a portion of the carbonaceous material.
31. The method of claim 30 , further comprising introducing an oxide of manganese into the carbonaceous material.
32. The method of claim 31 , wherein the step of introducing an oxide of manganese into the carbonaceous material comprises providing a solution comprising manganese nitrate and heating the solution and the carbonaceous material to form the oxide of manganese.
33. The method of claim 25 , wherein the substrate comprises titanium or aluminum.
34. The method of claim 25 , wherein the carbide comprises a metal carbide.