CN110923528B - 阳极铝箔的制造方法 - Google Patents
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 99
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- 238000005204 segregation Methods 0.000 claims abstract description 9
- 229910052684 Cerium Inorganic materials 0.000 claims abstract description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 5
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 5
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims abstract description 5
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 5
- 239000011651 chromium Substances 0.000 claims abstract description 5
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 5
- 239000011777 magnesium Substances 0.000 claims abstract description 5
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 5
- 229910052706 scandium Inorganic materials 0.000 claims abstract description 5
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 claims abstract description 5
- 239000011135 tin Substances 0.000 claims abstract description 5
- 229910052718 tin Inorganic materials 0.000 claims abstract description 5
- 229910052720 vanadium Inorganic materials 0.000 claims abstract description 5
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 5
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- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
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- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
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- WYXIGTJNYDDFFH-UHFFFAOYSA-Q triazanium;borate Chemical compound [NH4+].[NH4+].[NH4+].[O-]B([O-])[O-] WYXIGTJNYDDFFH-UHFFFAOYSA-Q 0.000 description 1
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Abstract
本发明公开了阳极铝箔的制造方法,涉及电解电容器技术领域,主要目的是提供高容量高折弯性能电解电容器阳极箔铝箔产品。采用的技术方案为:一种阳极铝箔,所述阳极铝箔由30‑100wt%的偏析初级原料和0‑70wt%的二级原料制备,所述阳极铝箔包括:Al≥99.9wt%,Fe:5‑35ppm,Si:5‑35ppm,Cu:60‑100ppm,Pb:0.2‑3ppm,Zn:2‑30ppm,Mn:2‑30ppm,Ga:2‑30ppm;所述阳极铝箔还包括:铈、钪、锆、钒、铬、镍、镁、锡中的一种或多种,且总含量为3‑25ppm。
Description
技术领域
本发明涉及电解电容器技术领域,尤其涉及阳极铝箔的制造方法。
背景技术
中高压铝电解电容器在空调、植入式心脏去纤颤器以及马达启动器等领域有广泛的应用。由于市场对电子设备小型化的需求,要求用于这些电子设备中的中高压铝电解电容器减少体积但同时保持或提升性能。因此用于中高压铝电解电容器的阳极铝箔需要提高比表面积以提高电容器的电容,增强阳极铝箔的力学性能尤其是折弯力学性能以满足不同形式电容器的需要,改善阳极铝箔的均匀性以提高电容器产品的一致性。
高性能中高压铝电解电容器的制备,一方面依赖于高纯铝板锭制成的阳极铝箔的腐蚀技术,另一方面取决于高纯铝扁锭制成的阳极铝箔本身的腐蚀性质。
目前国内生产的电解电容器阳极铝箔不能满足市场上高容量高折弯的性能要求,特别是日本高端腐蚀箔市场,还主要是使用日本本土生产的高压电解电容器用阳极铝箔。
发明内容
有鉴于此,本发明提供,主要目的是提供高容量高折弯性能电解电容器阳极箔铝箔产品。
为达到上述目的,本发明主要提供如下技术方案:
本发明提供了一种阳极铝箔的制造方法,所述阳极铝箔由30-100wt%的偏析初级原料和0-70wt%的二级原料制备,所述阳极铝箔包括:Al≥99.9wt%,Fe:5-35ppm,Si:5-35ppm,Cu:60-100ppm,Pb:0.2-3ppm,Zn:2-30ppm,Mn:2-30ppm,Ga:2-30ppm;
所述阳极铝箔还包括:铈、钪、锆、钒、铬、镍、镁、锡中的一种或多种,且总含量为3-25ppm;
所述阳极铝箔的制造方法包括如下工艺步骤:
步骤一,将偏析原料通过半连续铸造法铸造成高纯铝扁锭;
步骤二,将所述高纯铝扁锭经铣面、退火、降温热轧,得第一高纯铝带材;
步骤三,将所述第一高纯铝带材依次经多道次冷轧、箔轧,得第三高纯铝带材;
步骤四,将所述第三高纯铝带材依次加油清洗、烘干、中间退火、成品道次轧制,得第一铝箔,中间退火时,采用空气作为退火介质,2-8小时升温至240-270℃,并保温15-30h;
步骤五,将所述第一铝箔分切成剪切卷,将所述剪切卷进行多级退火处理,得成品;
其中,在多级退火处理时,2-6小时炉温升至250-330℃,保温3-8h,然后3-7h炉温升至350-420℃,保温8-15h,随后2-8h炉温升至480-530℃,保温6-12h,接着3-6h炉温升至580-620℃,炉温降至500-540℃,保温3-10h,得成品。
优选的,Pb的含量为2-2.5ppm。
优选的,Zn的含量为10-20ppm。
优选的,Mn的含量为5-10ppm。
优选的,在步骤二中,退火温度为540-620℃,且保温20-50h,热轧温度为480-560℃。
优选的,在步骤二中,热轧时,每道次压下率为40-70%,所述第一高纯铝带材的厚度为4-8mm。
优选的,在步骤三中,所述第一高纯铝带材经多道次冷轧后,得第二高纯铝带材,所述第二高纯铝带材的厚度为0.2-0.6mm。
优选的,在步骤四中,清洗速度为70-120m/min,烘干温度为90-150℃,所述第一铝箔的厚度为0.06-0.200mm。
本发明的优点和有益效果在于:
本发明通过使用30wt%-100wt%偏析初级原料和0wt%-70wt%的二级原料制备高纯铝扁锭,并通过熔铸工艺、热轧工艺、清洗、中退工艺、成品退火工艺,生产高压电解电容器用阳极铝箔,产品的(100)面织构占比达到98%以上。
附图说明
图1为本发明实施例一提供的成品的宏观立方织构图;
图2为本发明实施例二提供的成品的宏观立方织构图;
图3为本发明实施例六提供的成品的宏观立方织构图;
图4为本发明实施例八提供的成品的宏观立方织构图;
图5为本发明实施例二提供的腐蚀后成品表面的扫描电镜图;
图6为本发明实施例二提供的腐蚀后成品截面的扫描电镜图;
图7为对照例提供的腐蚀后成品表面的扫描电镜图;
图8为对照例提供的腐蚀后成品截面的扫描电镜图。
具体实施方式
下面结合实施例,对本发明的具体实施方式作进一步描述。以下实施例仅用于更加清楚地说明本发明的技术方案,而不能以此来限制本发明的保护范围。
在详细阐述本发明降低化成铝箔漏电的方法之前,有必要对本发明中提及的相关材料做进一步说明,以达到更好的效果。本发明中:
二级原料为阳极铝箔生产过程中产生的边角料、废料等。
在了解了上述相关材料及其选取之后,即可着手了解阳极铝箔的制造方法。下面将结具体的实施例,对本发明阳极铝箔的制造方法做进一步的详细介绍:
实施例
步骤一,将偏析初级原料和二级原料通过半连续铸造法铸造成高纯铝扁锭;半连续铸造时的冷却水速度控制在2000-3600L/min;铸造速度控制在42-50mm/min;铸造温度控制在680-720℃范围内。这样生产的高纯铝扁锭组织均匀,表面冷隔等缺陷少。
步骤二,将高纯铝扁锭经铣面、均匀化退火,均匀化退火温度在540-620℃,均匀化退火时间在20-50h,然后降温,在480-560℃热轧,得第一高纯铝带材。
在热轧扁锭时,采取大压下率,将晶粒破碎、细化中部组织,每道次的压下率均在40-70%之间,在保证不出现过大载荷影响表面质量的情况下使整个扁锭的晶格组织最终一致且细小;在单道次大加工率生产下,确保板型一致性,采用弯辊控制方式热轧加工变形率在0-90%之间,弯辊采用平衡轧制,热轧加工变形率在90-95%之间,弯辊采用负弯10-20%轧制,热轧加工变形率在95-97%之间,弯辊采用负弯20-30%轧制,热轧加工变形率97%以上时,弯辊采用负弯30-50%轧制。热轧完成后,第一高纯铝带材的厚度为4-8mm。
步骤三,将第一高纯铝带材经过多道次冷轧生产,得第二高纯铝带材,第二高纯铝带材的厚度为0.2-0.6mm,然后进行箔轧,得第三高纯铝带材。
步骤四,将第三高纯铝带材加油清洗,清洗速度控制在70-120m/min,保证箔面烘干,减少清洗剂(油)的残留,放置于烘干箱烘干,烘干箱温度控制在90-150℃。
然后,在2-8小时升温到240-270℃,在240-270℃保温15-30h,以达到表面除油及中间退火的目的。在中间退火时,采用空气作为退火介质。
然后,进行成品道次轧制,得第一铝箔,第一铝箔的厚度为0.06-0.200mm。
步骤五,将第一铝箔分切成宽度为450-550mm,重量为200-800Kg的剪切卷。
将剪切卷进行多级退火,首先,炉温2-6小时升温到250-330℃,保温3-8小时后,炉温3-7小时升温到350-420℃,保温8-15小时后,随后,炉温在2-8小时内升温到480-530℃,保温6-12小时后,接着炉温在3-6小时升温至580-620℃,保温至剪切卷温度达到500-540℃后,炉温降至500-540℃,继续保温3-10h,出炉,得成品。
所得成品的成分如下:
Al≥99.9wt%,Fe:5-35ppm,Si:5-35ppm,Cu:10-100ppm,Pb:0.2-3ppm,Zn:2-30ppm,Mn:2-30ppm,Ga:2-30ppm,微量元素(铈、钪、锆、钒、铬、镍、镁、锡中的一种或多种):3-25ppm。
其中,Pb的含量优选为2-2.5ppm。Pb元素在电子铝箔表面的氧化层富集,在初期腐蚀时,起到促进腐蚀的作用。Pb含量较少时,初期腐蚀发孔不足,容量无法提升。Pb含量过高时,腐蚀并孔较多,产品不耐腐蚀,折弯强度降低。
其中,Zn的含量优选为10-20ppm。Zn元素有促进电子铝箔腐蚀发孔的作用,特别是对腐蚀孔的长度有影响,对高厚度的电子铝箔产品影响明显。其次Zn含量对提高电子铝箔产品强度,防止粗大晶粒方面有较强的效果。
其中,Mn的含量优选为5-10ppm。Mn元素对产品的腐蚀发孔起到促进作用,适量的Mn元素能增加腐蚀发孔的孔径,能提升电子铝箔产品的静电容量。但是Mn含量过高时,容易造成腐蚀并孔,导致发孔不均匀,容量降低,折弯性下降。
对照例
在阳极铝箔的制造过程中,高纯铝扁锭的60wt%是采用偏析法制备的,另外的40wt%的高纯铝扁锭采用三层电解法制备。所述高纯铝扁锭包括:Al≥99.9wt%;Fe:10ppm;Si:l0ppm;Cu:60ppm。其它Pb:0.5ppm;Zn:3ppm;Mn:3ppm;Ga:8ppm。其它铈、钪、锆、钒、铬、镍、镁、锡中的一种或多种,且总含量为10ppm。
由实施例和对照列,得到原料和组份对照表,如下所示:
表1
对成品的表面质量进行检测,采用如下方法:
(1)将成品在50%HNO3、45%HCl、5%HF的混合液中常温腐蚀40s后,清洗烘干判定阳极箔立方织构含量占比。
(2)将成品在0.5mol/L的HCI与2.5mol/L的H2SO4的混合酸中、81℃的腐蚀温度下,在电解槽中通入0.5A/cm2的直流电85s,进行一次腐蚀。然后将成品在0.5mol/L的Al(N03)3与0.8mol/L的HNO3溶液中、90℃的腐蚀温度下,在电解槽中通入0.2A/cm2的直流电80s,进行二次腐蚀。腐蚀后,将铝箔置于10%的硼酸溶液中,在590Vf进行化成处理,然后在5%的硼酸铵中测定静电容量,并使用曲率半径为1.0mm的折弯仪测定阳极铝箔的折弯强度。
如图1、图2、图3和图4所示,白点为非立方织构,白点少且均匀,说明立方织构含量高,分布均匀。
将图5和图7对比可知,实施例二中成品表面腐蚀发孔相对均匀,并孔少。
将图6和图8对比可知,实施例二中成品截面腐蚀发孔长度相对均匀,芯层厚度适中,成品的容量及折弯性能都有所提升。
将实施例和对照例所得成品的检测结果整理如下:
表2
综上所述,由表1和表2得知,本发明实施例通过使用30wt%-100wt%偏析初级原料和0wt%-70wt%的二级原料制备高纯铝扁锭,并通过熔铸工艺、热轧工艺、清洗中间退火工艺、成品退火工艺等,生产高压电解电容器用阳极铝箔。所得成品的性能如下:(1)(100)立方织构占比也可达到98%以上;(2)在590Vf腐蚀化成后,成品的容量能达到0.70uf/cm2(对照例中,成品的容量只能达到0.65uf/cm2);(3)折弯可大于55回;(4)幅宽方向上的容量散差控制在5%以内,产品通过世界先进腐蚀箔生产企业日本JCC的高端腐蚀工艺测试,产品的各项性能指标达到世界先进水平。
第三高纯铝带材需要经过清洗工序,清洗去除表面的轧制油和铝粉等附着物质,但始终无法做到完全清除干净,同时箔面带有清洗油。这些表面附着物容易烧结在表面,易导致成品的表面一致性较难控制,从而影响腐蚀。本发明实施例中采用多级退火方式,在低温段(250-330℃)有一定的保温时间,该保温段有利于去除清洗后的表面附着物和清洗油,减少表面附着,从而可以提高成品的表面一致性。
其中,在中间退火时,采用空气作为退火介质,取消惰性气体作为保护气体,相对于现有技术,有效降低生产成本。
在中间退火时,不需要配置保护性气体退火的供气系统、自动充气控制系统、氧含量检测系统,降低设备投入,采用吸入空气进行冷却,冷却时间短、效率高,综合成本更低。
同时,在空气气氛下退火,提高了表面横向的氧化膜一致性。电子铝箔产品经腐蚀后幅宽方向的容量离散率在原有基础上降低30%,腐蚀后表面均匀性提高。
以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应以所述权利要求的保护范围为准。
Claims (8)
1.一种阳极铝箔的制造方法,其特征在于,所述阳极铝箔由30-100wt%的偏析初级原料和0-70wt%的二级原料制备,所述阳极铝箔包括:Al≥99.9wt%,Fe:5-35ppm,Si:5-35ppm,Cu:60-100ppm,Pb:0.2-3ppm,Zn:2-30ppm,Mn:2-30ppm,Ga:2-30ppm;
所述阳极铝箔还包括:铈、钪、锆、钒、铬、镍、镁、锡中的一种或多种,且总含量为3-25ppm;
所述阳极铝箔的制造方法包括如下工艺步骤:
步骤一,将偏析原料通过半连续铸造法铸造成高纯铝扁锭;
步骤二,将所述高纯铝扁锭经铣面、退火、降温热轧,得第一高纯铝带材;
步骤三,将所述第一高纯铝带材依次经多道次冷轧、箔轧,得第三高纯铝带材;
步骤四,将所述第三高纯铝带材依次加油清洗、烘干、中间退火、成品道次轧制,得第一铝箔,中间退火时,采用空气作为退火介质,2-8小时升温至240-270℃,并保温15-30h;
步骤五,将所述第一铝箔分切成剪切卷,将所述剪切卷进行多级退火处理,得成品;
其中,在多级退火处理时,2-6小时炉温升至250-330℃,保温3-8h,然后3-7h炉温升至350-420℃,保温8-15h,随后2-8h炉温升至480-530℃,保温6-12h,接着3-6h炉温升至580-620℃,炉温降至500-540℃,保温3-10h,得成品。
2.根据权利要求1所述的阳极铝箔的制造方法,其特征在于,Pb的含量为2-2.5ppm。
3.根据权利要求1所述的阳极铝箔的制造方法,其特征在于,Zn的含量为10-20ppm。
4.根据权利要求1所述的阳极铝箔的制造方法,其特征在于,Mn的含量为5-10ppm。
5.根据权利要求1至4任一项所述的阳极铝箔的制造方法,其特征在于,在步骤二中,退火温度为540-620℃,且保温20-50h,热轧温度为480-560℃。
6.根据权利要求1至4任一项所述的阳极铝箔的制造方法,其特征在于,在步骤二中,热轧时,每道次压下率为40-70%,所述第一高纯铝带材的厚度为4-8mm。
7.根据权利要求1至4任一项所述的阳极铝箔的制造方法,其特征在于,在步骤三中,所述第一高纯铝带材经多道次冷轧后,得第二高纯铝带材,所述第二高纯铝带材的厚度为0.2-0.6mm。
8.根据权利要求1至4任一项所述的阳极铝箔的制造方法,其特征在于,在步骤四中,清洗速度为70-120m/min,烘干温度为90-150℃,所述第一铝箔的厚度为0.06-0.200mm。
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