General Descriptions of Aluminum Electolytic Capacitors

1. General Description of Aluminum Electrolytic Capacitors

1-1 Principles of Aluminum Electrolytic 1-2 Capacitance of Aluminum Electrolytic

Capacitors Capacitors
An aluminum electrolytic capacitor consists of cathode The capacitance of an aluminum electrolytic capacitor
aluminum foil, capacitor paper (electrolytic paper), may be calculated from the following formula same as for
electrolyte, and an aluminum oxide layer, which acts as a parallel-plate capacitor.
-- 8 εS
the dielectric, formed on the anode foil surface.
C = 8.855 10 (µF) (1 - 1)
A very thin oxide layer formed by electrolytic oxidation d
(formation) offers superior dielectric constant and has ε : Dielectric constant of dielectric
rectifying properties. When in contact with electrolyte, the S : Surface area (cm2) of dielectric
oxide layer possesses an excellent forward direction d : Thickness (cm) of dielectric
insulation property. Together with magnified effective
surface area attained by etching the foil, a high To attain higher capacitance "C", the dielectric constant
capacitance yet small sized capacitor becomes available. " ε " and the surface area "S" must be large while the
As previously mentioned, an aluminum electrolytic thickness "d" must be small. Table 1-1 shows the
capacitor is constructed by using two strips of aluminum dielectric constants and minimum thickness of dielectrics
foil (anode and cathode) with paper interleaved. This foil used in various types of capacitors.
and paper are then wound into an element and With aluminum electrolytic capacitors, since aluminum
impregnated with electrolyte. The construction of an oxide dielectric has excellent withstand voltage per
aluminum electrolytic capacitor is illustrated in Fig. 1-1. thickness. And the thickness of dielectric can be freely
controlled according to the rated voltage of the aluminum
Electrolyte electrolytic capacitor.
(Real Cathode)

,
Therefore, in compare to other dielectric, similar voltage

,,,,,,,
endurance is provided by aluminum oxide dielectric even
if thickness ("d" in the above formula) is thin.

,,,,,,
Anode aluminum
Cathode Aluminum Furthermore, by etching the surface of aluminum foil,

,
electrode

,,,,,,,
electrode
(Apparent Cathode)
the effective area of the foil as compared to the apparent
area can be enlarged 80~100 times for low voltage
capacitors and 30~40 times for middle / high voltage
Electrolytic paper
Oxide film containing electrolyte capacitors. Therefore, aluminum electrolytic capacitors
have a higher capacitance for a specified apparent area
Fig. 1 - 1
than other types of capacitors.
Since the oxide layer has rectifying properties, a High purity aluminum foil for the anode is etched by
capacitor has polarity. If both the anode and cathode foils electrochemical process in a chloride solution with DC,
have an oxide layer, the capacitors would be bipolar (non- AC, or an alteration of DC and AC, or a concurring AC and
pola) type capacitor. DC current. Fine surface etching (photo 1-1)
These technical notes refer to "non-solid" aluminum accomplished mainly by AC electrolysis is generally used
electrolytic construction in which the electrolytic paper is for low voltage foil. Tunnel etching (photo 1-2)
impregnated with liquid electrolyte. There is another type accomplished mainly by DC electrolysis is used for middle
of aluminum electrolytic capacitor, which is the "solid" that / high voltage foil. The ething of the cathode foil is mainly
uses solid electrolyte. accomplished by AC electrolysis to increase the surface
area.

Table 1-1 Dielectric constants and minimum thickness of dielectrics used in various types of capacitors

Type of Capacitor Dielectric Dielectric Constant ε Dielectric Thickness d (µm)

Aluminum Electrolytic Capacitor Aluminum Oxide 7~10 (0.0013~0.0015/ V)
Tantalum Electrolytic Capacitor Tantalum Oxide 24 (0.001~0.0015/ V)
Film Capacitor (Metallized) Polyester Film 3.2 0.5~2
Ceramic Capacitor (High Dielectric Constant Type) Barium Titanate 500~20,000 5
Ceramic Capacitor (Temp. Compensation Type) Titanium Oxide 15~250 5

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General Descriptions of Aluminum Electolytic Capacitors

Surface Section

Photo 1-1 Surface and section photo of etched aluminum foil for low voltage capacitors.

Surface Section (Replica)

Photo 1-2 Surface and section photo of etched aluminum foil for middle / high voltage capacitors.

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General Descriptions of Aluminum Electolytic Capacitors

1-3 Dielectric (Aluminum Oxide Layer)

A high purity etched aluminum foil is anodized in a 0.0013~0.0015 (µm/ V).
boric acid-ammonium water type solution, for exsample, Expanded photography of a dielectric (aluminum oxide
to form an aluminum oxide layer on its surface. This layer) on the foil that has not been etched (plain foil) is
aluminum oxide layer is what we call the dielectric of the shown in photo 1-3.
aluminum electrolytic capacitor. The DC voltage that is The fabrication reaction of the dielectric can be
applied to the foil to oxidize the anode foil is called expressed as follows:
"Forming Voltage". 1) Al3++6H2O [Al(OH2)6]3+
3+
The thickness of the dielectric is nearly proportional to 2) [Al(OH2)6] Al(OH)3+3H2O+3H+
the forming voltage and measures approximately 3) 2Al(OH)3 Al2O3+3H2O
dielectric

dielectric

dielectric
20V Fomed 100V Fomed 250V Fomed
Photo 1-3 Enlarged photo of oxide layer formed on a non-etched plain aluminum foil.

Photo 1-4 Enlarged photo of middle, high voltage formed foil.

(Condition of oxide layer formation in a pit)

1-4 Electrolyte
Anode foil and a cathode foil facing each other are (1) It must be electrically conductive
interleaved with electrolytic paper and wound into a (2) It must have a forming property to heal any flaws on
cylindrical shape. This is called a "capacitor element." At the dielectric oxide of the anode foil.
this stage, it has configuration of a capacitor when (3) It must be chemically stable with the anode and
considers electrolytic paper and the aluminum oxide layer cathode foils, sealing materials, etc.
to be dielectric, however, the unit has few capacitance. (4) It must have superior impregnation characteristics
When this capacitor element is impregnated with liquid (5) Its vapor pressure must be low.
electrolyte, the anode foil and cathode foil are electrically The above characteristics of electrolyte greatly
connected. With the aluminum oxide layer formed on the influence the various characteristics of aluminum
anode foil acting as the sole dielectric, a capacitor with a electrolytic capacitors. For this reason, the proper
high value of capacitance is now attainable. That is to say electrolyte is determined by the electrical ratings,
that the electrolyte is now functioning as a cathode. The operating temperatures and the application of the
basic characteristics required of an electrolyte are listed capacitor.
below:
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General Descriptions of Aluminum Electolytic Capacitors

1-5 Manufacturing Process of Aluminum

Electrolytic Capacitors
Process Main Materials Contents

High purity aluminum foil A 0.05~0.11 mm thick anode foil and a 0.02~0.05 mm thick
Etching
(Enlargement of the Chloride cathode foil are continuously etched electrochemically in a
Surface Area) chloride solution with an AC or DC current. This enlarges the
Pure water
effective surface area of the aluminum foils to attain smaller
capacitor sizes.

Etched foil The process develops aluminum oxide (Al203) to form a

Forming
(Formation of Borate, etc. capacitor dielectric.
the Dielectric) A high purity etched aluminum foil is anodized in a boric acid-
Pure water
ammonium water type solution, for exsample, to form an
aluminum oxide film on the surface of the cathode foil. As for
the anode foil, an low DC voltage is sometimes used for
formation, but there are also situations where formation is not
conducted.

Anode foil A foli is slit into specified widths according to capacitor case
Slitting sizes.
Cathode foil

Slited foils (anode/cathode) Anode and cathode foils interleaved with an electrolytic paper
Electrolytic paper are wound into a cylindrical capacitor element, with leads
Winding being connected to both foils.
Leade
Winding aftixing material
Lead
Winding aftixing
material

Element

Foil Electrolytic
paper
Fig. 1 - 2

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General Descriptions of Aluminum Electolytic Capacitors

Prosess Main Materials Contents

Elements are impregnated with liquid electrolyte.
Element The clearance between the two electrode foils is filled with
Elements
Impregnation liquid electrolyte. With this impregnation, an element can
Electrolyte Electrolyte function as a capacitor.
The impregnated element, case and end seal are assmbled.

Impregnated elements For the end seal , a rubber packing, a rubber lined bakelite
Assembly Case (usually aluminum) (with terminals) or a molded plastic plate (with terminals) are
& used.
Finishing End seal After assembly, the capacitors are covered with exterior
Rubber packing, housing material. Sleeving is not used for laminate case

( )
Rubber-bakelite with terminals products, such as surface mount capacitors.
Mold plastic with terminals
Exterior housing material
(Sleeving, bottom plate, etc.) Lead wire Aluminum rivet Terminal
Curled section Rubber-bakelite

,,, ,
,,,,
,,,,
, ,,
Aluminum lead tab Curled section Aluminum lead tab

,
Rubber packing Aluminum case

,,,,,,
,,,,
Sleeving

,,,
Aluminum case

Element
Sleeving
Element fixing material
Element (may or may not
,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,, be - used)
,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,

Bottom plate
Fig. 1 - 3 Fig. 1 - 4
Nylon laminate casing for laminate products (sleeveless)

Aging Assembled products DC voltage is applied under high temperature conditions to

reform the oxide film.

Leads are processed and the plastic platform is attached to

surface mount capacitors.
Plastic platform Depending on customer specification, the lead cutting,
Processing Taping material forming, snap - in and taping are processed.
Accessories, such as mounting braket, are attached.
Accessories
(Capacitor mounting braket
terminal screws , etc.)
,,,,
,,,,
,,,,
,,,

Fig. 1 - 5

Inspection An inspection based on the standard specification and test

requirements is performed to guarantee the quality of
products.

Packaging Packaging materials

Shipping

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General Descriptions of Aluminum Electolytic Capacitors

1-6 Characteristics
1-6-1 Capacitance The impedance can be expressed by :
The capacitance of the dielectric portion of the anode 1
+ jw L + R
jω C
Z=
aluminum foil can be calculated with the following formula
(discussed in 1-1) : Its absolute value can be expressed by :

ε S (µF) Z = R2+(ω L -- ω C )
-- 8
1 2
Ca = 8.855 10
d Its relation with frequencies is shown by a model curve.
The cathode foil has a capacitance (Cc) that uses the The inductance "L" is mainly from the wound electrode
oxide film, which formed by the forming voltage or formed foils and the leads.
naturally during storage (generally it should be 1V or less), ESR "R" is from resistance of the electrode foils, the
as a dielectric. According to the construction of aluminum electrolyte, the leads and each connection.
electrolytic capacitors, Ca and Cc are connected in a
series. Therefore, the capacitance can be determined by
the following formula:
Ca C c
C= 10
Ca + Cc

The standard capacitance tolerance is 20%(M);

however, capacitors with a capacitance tolerance of 1

R (Ω), Z(Ω)
10%(K), etc. are also manufactured for special usage.
The capacitance of aluminum electrolytic capacitors
changes with temperature and frequency of measurement, 10-1
so the standard has been set to a frequency of 120Hz and Z
o
temperature of 20 C. R
10-2
Xc XL

1-6-2 Equivalent Series Resistance (R), Dissipation

10-3
Facter (tanδ), Impedance (Z) 102 103 104 105 106
The equivalent circuit of an aluminum electrolytic Frequency (Hz)
capacitor is shown below, The equivalent series resistance
is also known as "ESR". Fig. 1 - 8

C Capacitance (F)
r
R L r Equivalent parallel resistance of
1-6-3 Leakage Current
anode oxide film (Ω)
C The causes of leakage current in aluminum electrolytic
R Equivalent series resistance (Ω)
Fig. 1 - 6 capacitors are listed below :
L Equivalent series inductance ( H )
1)Distorted polarization of dielectric (aluminum oxide
A reactance value due to the equivalent series layer)
inductance "L" is extremely small at low frequencies 2)Resolution and formation of dielectric
(50Hz~1kHz) and can be regarded as zero. Therefore, 3)Moisture absorption by dielectric
the following formula can be set up. 4)Breakdown of dielectric due to the existence of
chlorine or iron particles.
tanδ = =ωCR
Z R (1 - 2) The leakage current value can be decreased by proper
Xc
selection of materials and production methods; however,
DF = tan δ 100 (%) (1 - 3)
cannot be totally eliminated.
δ
PF = cos θ
Xc R R
= = (1 - 4) Leakage current is also dependent upon time, applied
(1/ωc)
Z 2

θ
2
R + ( ω1C ) voltage and temperature.
1 Xc
(1 - 5)
The specified leakage current value is measured after
tan δ
Q = = R
R the rated voltage of the capacitor is applied at room
(ω = 2 π f) temperature for a specified time period. When selecting a
Fig. 1 - 7 capacitor for a particular application, characteristics such
as temperature dependency, aging stability and etc. must
be taken into account.

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General Descriptions of Aluminum Electolytic Capacitors

1-6-4 Temperature Characteristics

10 50V 1000µF 105oC
Aluminum electrolytic capacitors have liquid electrolyte.
This electrolyte has properties (conductivity, viscosity,
etc.) that have rather conspicuous temperature
-25oC
characteristics. 1
Electrical conductivity increases as the temperature
+20oC
increases and reduces as the temperature decreases. +65oC

tan δ
Therefore, the electrical characteristics of aluminum +105oC

electrolytics are affected by temperature more than other 0.1

types of capacitors. The following section explains the
relationship between temperature and capacitance,
tangent delta, ESR, impedance and leakage current.
0.01
1) Capacitance 100 1k 10k
The capacitance of aluminum electrolytic capacitors Frequency (Hz)

increases as the temperature increases and decreases as 10 200V 470µF 105oC

-25oC
the temperature decreases. The relationship between
temperature and capacitance is shown in Fig. 1-9.
1
2) Tanδ, Equivalent Series Resistance (ESR), Impedance +20oC
The Tanδ, equivalent series resistance (ESR) and
+65oC

tan δ
impedance changes with temperature and frequency. An
+105oC
example of the general characteristics is shown in Fig. 1-
0.1
10 and 1-11.

20
50V 1000µF 105o C
0.01
Capacitance change (%)

10 100 1k 10k
Frequency (Hz)
0
at 120HZ Fig. 1 - 10 Tanδ vs. Frequency
-10 Characteristics
-20
10
-30 50V 1000µF 105oC

-40
-60 -40 -20 0 20 40 60 80 100 120
Temperature (o C) 1
Impedance( Ω )
ESR( Ω )

20
200V 470µF 105 o C Impedance
Capacitance change (%)

10 -25oC ESR
0.1
0
at 120HZ
-10 +20oC
+65oC
-20 0.01 +105oC
100 1k 10k 100k
-30
Frequency (Hz)
-40 10
-60 -40 -20 0 20 40 60 80 100 120 200V 470µF 105oC
Temperature (o C)
-25oC
Fig. 1 - 9 Capacitance vs. Temperature Characteristics 1
Impedance( Ω )
ESR( Ω )

Impedance
ESR
+20oC
0.1

+65oC

0.01 +105oC
100 1k 10k 100k
Frequency (Hz)
Fig. 1 - 11 Impedance, ESR vs. Frequency
Characteristics

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General Descriptions of Aluminum Electolytic Capacitors

3) Impedance Ratio
o
The ratio between the impedance at 20 C and the
1000
impedance at various temperatures is called the 50V 1000 µF 105oC
impedance ratio. Impedance ratio becomes smaller as Measured after 1 minute
application of rated voltage
smaller change of ESR and capacitance with temperature.

Leakage current (µA)

The quality of performance at low temperatures is 100
particularly expressed with the impedance ratio at 120Hz.

4) Leakage Current
10
The leakage current increases as the temperature
increases and decreases as the temperature decreases.
Fig. 1-12 shows the relationship between temperature and
1
leakage current.
-20 0 20 40 60 80 100 120
Temperature (oC)

1000
200V 470 µF 105oC
Measured after 5 minutes
application of rated voltage

Leakage current (µA)

100

10

1
-20 0 20 40 60 80 100 120
Temperature (oC)

Fig. 1 - 12 Leakage current vs. Temperature Characteristic

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