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Патент USA US2404824

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July 30, 1946.
Filed Feb. 10, 1942
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PatentedrJuly 3o, 1946v
James Marvin Booe, Indianapolis, Ind., asslgnor
to F. R. Mallory & 00., Inc., Indianapolis, Ind.,
a corporation of Delaware
Application February 10, 1942, Serial No. 430,113
'1 Claims. (Cl. 175-315)
This invention relates to electrolytic condens
generic in their application to similar parts as
the art will permit.
An object of the invention is to improve elec
trolytic condensers and the electrodes therefor,
and particularly to improve dry electrolytic con
Other objects of the invention will be appar
ent from the following description and accom
panying drawing taken in connection with the
appended claims,
The invention comprises the features of con
struction, combination of elements, arrangement
of parts, and methods of manufacture and oper
Referring to the drawing, Figure 1 shows a
method of producing the ?exible electrode which
comprises leading a strip of cloth l0 over a roller
l i and simultaneously spraying a deposit of ?lm
forming metal [2, such as aluminum, onto the
cloth by a Schoop spray gunv 13 as it is led over
the roller.
While a variety of porous or ?brous bases may
be used, the preferred material is a relatively
loose woven open-mesh cotton cloth of high pur
ity. Muslin, cheesecloth, cotton gauze and the
like are especially suitable in the various ‘weights
ation referred to above or which will be brought
out and exempli?ed in the disclosure hereinafter 16 and thread spacings obtainable commercially.
The cloth should preferably'be bleached and un
set forth, including the illustration in the draw
sized and free of impurities such as chlorides.
In the drawing:
The spraying time and density are preferably
regulated was to produce a sheet which is por
Fir-‘ire 1 shows the initial step in the meth
20 ous and ?exible enough to roll without cracking
of preparing a condenser electrode;
Figure 2 illustrates a subsequent step which
but in which the sprayed metal particles are
comprises rolling the electrode between pressure
bonded together su?iciently to conduct electric
v rolls;
Figure 3 illustrates a completed electrode;
Figure 4 is a section through a portion of a
modi?ed form of electrode; and
Figure 5 is a sectional view of a completed con
This invention relates particularly to electro
ity throughout the sheet, thereby forming a po
rous coherent and adherent layer of metal par
According to the present invention the elec
trode sheet or strip formed in this manner is
compressed, as by rolling, as illustrated'in Fig
It will usually be found desirable to chem
lytic condensers having at least one of their elec 30 ically clean the sheet electrode, however, before
trodes formed of a ?nely divided ?lm-forming
rolling. This may preferably be done by boil
metal, such as aluminum, deposited in cohering
ing the sprayed electrode for a short time, such
?nely divided form upon a porous ?exible sheet
as two minutes, in a dilute borax solution, such
base such as cloth or gauze. The ?lm-forming
as a 0.1% borax solution. It is found that this
metal is preferably deposited by a metal spray 35 cleaning before rolling results in an increase in
process using a metal spray gun wherein metal
capacity of the ?nished condenser. Or the borax
particles are sprayed and simultaneously heated
or melted.
According .to the present invention the elec
ure 2.
‘ cleaning will permit a greater reduction in thick
ness without increasing the power factor or re
ducing the capacity of the condenser ‘produced
trode element comprising a porous or ?brous base 40 from the electrode.
carrying a coherent adhering layer of ?nely di
vided ?lm-forming metal particles, is subjected
to pressure to reduce its thickness and compress
It also reduces the power
and chemicals required for electrolytic ?lm-for
mation, shortens the aging time of the condénsr
ers and results in a better shelf life and a longer
the porous electrode metal layer. This is prefer
life for the condensers.
ably accomplished by rolling the electrode be 45 operating
The cloth layer 10 carrying spray deposited
tween cooperating calendering rolls of hardened
aluminum particles I2 is rolled and thereby re
steel or the like.
duced in thickness by passing it between a pair
While a preferred embodiment of the inven
of cooperating steel rollers l4, l5 as shown in
tion is described herein, it is contemplated that
considerable variation may be made in the meth 50 Figure 2, thereby resulting in a rolled electrode
l8 which is thinner than the original sprayed
od of procedure and the construction of parts
cloth layer.
without departing from the spirit of the inven
The rolls may be spaced so as to reduce the
tion. In the following description and in the
thickness of the electrode as much as 36%. Thus
claims, parts will be identi?ed by speci?c names
for convenience, but they are intended to be as 55 if the original thickness is .0165 inch on the
~ 2,404,824
average, the ?nal thickness may be .0105 inch
representing a reduction of 36.4%.
After rolling, the electrode is ?lm-formed in a
well-known manner. If the electrode has been
‘cleaned before rolling. as described, it is bene
?cial to dry the electrode after rolling and be
fore ?lm-formation. Whether the electrode is
rolled wet or dry is not material but it is unde
sirable to allow it to remain wet for any exten
. and adds practically nothing to the cost of pro
ducing the electrodes.
While the present invention, as to its objects
and advantages, has been described herein as car
ried out in speci?c embodiments thereof, it is not
desired to be limited thereby but it is intended to
cover the invention broadly within the spirit and
scope of the appended claims.
What is claimed is:
sive period after it has been cleaned in the borax
1, An electrolytic condenser comprising coop
cleaning operation.
erating electrodes and an electrolyte in contact
Figure 3 shows a completed condenser elec
therewith, at least one Of said electrodes com
trode comprising the rolled electrode layer I8 and
prising a compressed layer of ?nely divided
a terminal I‘! secured thereto by punching the
cohering particles of ?lm-forming metal.
two parts together as indicated at l8.
2. An electrolytic condenser comprising coop
The invention is also applicable to condenser
erating electrodes and an electrolyte in contact
electrodes formed of two cloth layers l9 and 20
therewith, at least one of said electrodes com
cemented together by the ?lm-forming metal
prising a compressed layer of ?nely divided
spray deposit 2! as illustrated in Figure 4.
cohering particles of aluminum metal.
Figure 5 shows a completed condenser com 20
3. A dry electrolytic condenser comprising co
prising a condenser section 22 produced by wind
operating sheet electrodes wound together with
ing together alternate electrode layers l6 and
porous sheet spacers impregnated with a ?lm
spacer layers of porous paper, cloth, regenerated - maintaining electrolyte, at least one of said elec
sheet cellulose or the like. The condenser sec
trodes comprising a ?brous sheet base carrying a
tlon 22 is impregnated with a suitable ?lm-main 25 compressed'adhering layer of cohering ?lm-form
taining electrolyte and inclosed in a container
ing metal particles, said layer having a dielectric
23 having a laminated top 24. Terminal i1
?lm thereon.
passes through the laminated top and is con
4.,A dry electrolytic‘ condenser comprising co
nected to a soldering lug 25 mounted in the top.
_ operating sheet electrodes wound together with
The opposite condenser electrode is connected to 30 porous sheet spacers impregnated with a ?lm
container 23 by a terminal strip 26 which is spun
maintaining electrolyte, at least one of said elec
under the edge of the top.
The reduction in thickness brought about by
rolling surprisingly does not reduce the capac
ity per unit area, of the electrodes. In fact, in
most cases an increase in capacity has been ob
tained, the increase frequently amounting to 10%
or more.
The power factor and resistance of the con
denser is not materially altered.
Due to the reduced thickness at smaller con
trodes comprising a cloth base carrying a com
pressed adhering layer of cohering ?lm-forming
metal particles, said layer having a dielectric ?lm
5. An electrode for electrolytic condensers com
prising a cloth base carrying an adhering layer
of ?lm-forming metal, said layer comprising a
compressed cohering spray deposit of aluminum.
6. A dry electrolytic condenser comprising co
operating sheet electrodes wound together with
denser section can be produced from the same
porous sheet spacers impregnated with a ?lm
area electrode making it possible to provide a
maintaining electrolyte, at least one of said elec
smaller condenser unit for a given capacity. This
trodes comprising a cloth base carrying a chem
also results in a saving in the amount of elec 45 ically-cleaned and compressed adhering iayer of
trolyte used, this saving in some cases amount
cohering aluminum particles, said layer having a
ing to 15 or 20% of the electrolyte.
continuous dielectric ?lm thereon.
Life tests made on condensers using rolled elec
7 A dry electrolytic condenser comprising co
trodes are as good as or slightly better than those
operating sheet electrodes wound together with
on condensers using sprayed electrodes which
porous sheet spacers impregnated with a ?lm
have not been rolled.
maintaining electrolyte, at least one of said elec
Rolling also insures better electrical con
trodes comprising a double thickness of open—
ductivity throughout the electrode layer and in
mesh cloth bonded together with a porous co
creases the reliability of electrodes made from a ’
hering spray-deposit of aluminum, said bonded
single cloth layer sprayed with a relatively light 55 electrode being uniformly compressed so that its
coating of aluminum. While the rolling hardens
thickness is less than that of said electrode in
the electrode layer slightly, it does not interfere
the “as sprayed” condition, said spray-deposit
With the winding of the electrode into a roll in
having a dielectric film thereon.
producing a condenser.
The rolling step is simple and easy to perform 60
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