WO1998030348A1 - Binder removal - Google Patents

Binder removal Download PDF

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Publication number
WO1998030348A1
WO1998030348A1 PCT/GB1998/000023 GB9800023W WO9830348A1 WO 1998030348 A1 WO1998030348 A1 WO 1998030348A1 GB 9800023 W GB9800023 W GB 9800023W WO 9830348 A1 WO9830348 A1 WO 9830348A1
Authority
WO
WIPO (PCT)
Prior art keywords
binder
article
solution
derivative
water
Prior art date
Application number
PCT/GB1998/000023
Other languages
French (fr)
Inventor
Ian H. Bishop
David Masheder
Original Assignee
Avx Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Avx Limited filed Critical Avx Limited
Priority to AT98900293T priority Critical patent/ATE223274T1/en
Priority to EP98900293A priority patent/EP0951374B1/en
Priority to DE69807650T priority patent/DE69807650T2/en
Priority to AU54904/98A priority patent/AU5490498A/en
Priority to IL13089298A priority patent/IL130892A/en
Priority to KR10-1999-7006307A priority patent/KR100494140B1/en
Priority to JP53062998A priority patent/JP4230541B2/en
Publication of WO1998030348A1 publication Critical patent/WO1998030348A1/en
Priority to US09/351,637 priority patent/US6197252B1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
    • H01G9/004—Details
    • H01G9/04—Electrodes or formation of dielectric layers thereon
    • H01G9/048—Electrodes or formation of dielectric layers thereon characterised by their structure
    • H01G9/052—Sintered electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B22F3/1025—Removal of binder or filler not by heating only

Definitions

  • the present invention relates to the field of forming articles by pressing of particulate matter bound by a binder/lubricant, and more particularly to methods of manufacturing components of high purity sintered articles in which the binder is removed after pressing and before sintering .
  • the anodes are typically formed by mixing tantalum powders with a small quantity of binder / lubricant, compacting and moulding the mixture to form the required shape and subsequently removing the binder by heating under vacuum so that the binder sublimes, distils or decomposes. After removal of the binder, the anodes are sintered to fuse the powder into an integral article.
  • binder/lubricant material in electrical or other high purity applications is limited by the requirement that little or no carbonaceous residues should be left after the vacuum heating process, and that no oxygen is added to the anode by the removal process. The presence of such residues alters the electrical properties of the capacitor by degrading the anodic oxide film deposited onto the sintered tantalum product. Binders currently used include camphor, certain waxes and certain polymers.
  • United States patent specification no. 5,470,525 discloses a method of removing binder from tantalum powder pellets by leaching in warm aqueous detergent solutions, followed by washing in clean water.
  • the leaching process takes a considerable amount of time, typically many hours.
  • a method of removing water-insoluble binder from a porous article formed from pressed particulate material comprising contacting the article with an aqueous solution of an agent which reacts with said binder to produce a water-soluble derivative thereof whereby said binder derivative may be substantially dissolved in said solution.
  • the present invention removes the binder by chemical reaction and dissolution of highly soluble reaction products.
  • the binder may be removed without the complicated distillation or high temperature heating processes of the prior art, and at a rate which is considerably faster than known heated leaching processes.
  • the contact may be effected by immersion of the article in a fluid containing or comprising the said agent. In this way fluid enters the article through pores present therein to contact with the binder.
  • the contact is effected by immersing the article in an aqueous solution of the agent .
  • the aqueous solution may be heated to facilitate the removal of binder from the article.
  • the temperature of the solution is preferably above the melting point of the binder whereby the binder liquifies when immersed in the solution.
  • the binder material may be a higher fatty acid.
  • the modification process may comprise hydrolysis of the acid in the presence of an alkaline solution.
  • the salt of the fatty acid is formed, which salt dissolves into solution to effect removal of the binder.
  • a preferred fatty acid is stearic acid.
  • Fatty acids are cheap, readily available and very effective binder / lubricants.
  • their use up to date for high purity applications has been restricted by the difficulty of completely removing the binder after pressing and by their high carbon content which makes residues particularly damaging for certain high purity applications .
  • the binder may comprise a mixture of the water-insoluble binder material and a water-soluble material.
  • a water soluble material may be a long chain alcohol such as a polyethylene glycol .
  • a preferred combination is a fatty acid such as stearic acid and a polyethylene glycol. In some embodiments up to 5% by weight of fatty acid is added to up to 5% by weight of glycol.
  • Polyethylene glycol is a good binder and fatty acid a good lubricant. Together, the two components form a mixture which gives good processability in the formation of the "green" articles.
  • the aqueous solution may include hydroxide ions introduced by adding an hydroxide which dissociates in water.
  • hydroxide ions introduced by adding an hydroxide which dissociates in water.
  • Typical examples are sodium hydroxide, potassium hydroxide, ammonium hydroxide and the like.
  • the hydroxide should be added in sufficient proportions to ensure stoichio etric reaction which the binder, whilst retaining low viscosity which permits effective penetration of the article.
  • the fluid may be stirred or otherwise agitated during the removal process.
  • the article itself may be agitated while immersed thereby enhancing the penetration of fluid into the article.
  • Suitable agitation apparatus will be known to the person skilled in the art.
  • any binder derivative remaining in the article may be removed by washing of the article in clean water.
  • the washing process may be repeated to ensure complete removal of modified binder.
  • the progress and effectiveness of the washing process may be monitored by measuring the conductivity of the of each wash solution; remaining metallic ions in solution will give relatively high conductivity readings .
  • the article After washing the article may be dried and then sintered to form a consolidated product.
  • the particles may be metallic for example niobium, aluminium, tantalum and other anodisable metals.
  • the particles comprise tantalum powder.
  • the article may be configured to be the anode of a capacitor. Such articles range in size from about 0.6mm cubed to cylinders about 6mm in diameter and 7mm long .
  • the present invention has particular application in the production of tantalum capacitors whereby tantalum powder anodes are formed from sintered tantalum powder and then incorporated into the capacitor.
  • tantalum powder anodes are formed from sintered tantalum powder and then incorporated into the capacitor.
  • Tantalum powder is mixed with a small quantity (5% by weight) of stearic acid (CH 3 -[CH 2 ] 16 -C00H) binder / lubricant. The mixture is then pressed to form a shaped article, in this example the anode component of a solid state capacitor.
  • stearic acid CH 3 -[CH 2 ] 16 -C00H
  • the article is then immersed in 0.5% aqueous sodium hydroxide solution heated to about 80 'C for about 30 minutes to effect reaction. During this time the article is agitated to ensure complete penetration of the article by the solution, and also to ensure that un- reacted solution is continually introduced into the article while reaction products dissolve into the bulk solution .
  • the article is removed from the solution and washed in clean water to remove any remaining stearate present in the pores of the article.
  • the washing step may be repeated to ensure complete cleaning.
  • the conductivity of the cleaning solution can be sampled by conventional methods to give an indication of the sodium ion concentration. As the sodium ions are washed away, conductivity of the wash solution decreases until the required cleanliness is achieved.
  • the binder comprises a mixture of stearic acid and polyethylene glycol with an average molecular weight of 2000. The acid and glycol are present in weight percentages of 4% and 0.5% respectively (as a percentage of tantalum weight). The rest of the process variables are substantially identical.
  • the process chemicals used in the methods of the present invention are relatively low hazard, cheap and easily disposable with a low environmental impact.
  • Tantalum anodes produced in a method according to the present invention are very low in carbon because the carbonaceous materials are, in effect, completely removed. Furthermore, negligible quantities of oxygen are added during the binder removal process due to the low temperatures possible in the removal process of the present invention. Because of this the electrical characteristics of the finished articles are significantly improved. In particular, the reliability of the capacitors is increased and current leakage in use is reduced.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Powder Metallurgy (AREA)
  • Lubricants (AREA)
  • Fixed Capacitors And Capacitor Manufacturing Machines (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
  • Braking Arrangements (AREA)
  • Inorganic Insulating Materials (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Ceramic Capacitors (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
  • Medicines Containing Material From Animals Or Micro-Organisms (AREA)
  • Treatment Of Liquids With Adsorbents In General (AREA)

Abstract

The invention relates to a method of removing water-insoluble binder from a porous article formed from pressed particulate material, such as tantalum powder. The invention provides a method capable of removing substantially all of the binder from the article for high purity applications, such as capacitor manufacture. The method comprises contacting the article with an aqueous solution of an agent which reacts with said binder to produce a water soluble derivative thereof whereby said binder derivative may be substantially dissolved in said solution. In a particular embodiment, the derivative is produced by hydrolysis of a fatty acid binder.

Description

Binder remov l
The present invention relates to the field of forming articles by pressing of particulate matter bound by a binder/lubricant, and more particularly to methods of manufacturing components of high purity sintered articles in which the binder is removed after pressing and before sintering .
In the manufacture of tantalum capacitors the anodes are typically formed by mixing tantalum powders with a small quantity of binder / lubricant, compacting and moulding the mixture to form the required shape and subsequently removing the binder by heating under vacuum so that the binder sublimes, distils or decomposes. After removal of the binder, the anodes are sintered to fuse the powder into an integral article.
The choice of binder/lubricant material (hereinafter "binder" ) in electrical or other high purity applications is limited by the requirement that little or no carbonaceous residues should be left after the vacuum heating process, and that no oxygen is added to the anode by the removal process. The presence of such residues alters the electrical properties of the capacitor by degrading the anodic oxide film deposited onto the sintered tantalum product. Binders currently used include camphor, certain waxes and certain polymers.
Even with these binders it is inevitable that a small amount of carbon will have been added to the anode because of incomplete removal of the binder or its decomposition products and residues. Furthermore small quantities of oxygen will also be present because of the heating cycle used for removal and because of oxygen present in the binder itself.
United States patent specification no. 5,470,525 discloses a method of removing binder from tantalum powder pellets by leaching in warm aqueous detergent solutions, followed by washing in clean water. However, in the method disclosed by the aforementioned specification, the leaching process takes a considerable amount of time, typically many hours.
It is an object of the present invention to provide a method of removing binder for high purity applications and which improves upon the known methods .
According to the present invention there is provided a method of removing water-insoluble binder from a porous article formed from pressed particulate material comprising contacting the article with an aqueous solution of an agent which reacts with said binder to produce a water-soluble derivative thereof whereby said binder derivative may be substantially dissolved in said solution.
Thus the present invention removes the binder by chemical reaction and dissolution of highly soluble reaction products. In this way the binder may be removed without the complicated distillation or high temperature heating processes of the prior art, and at a rate which is considerably faster than known heated leaching processes.
The contact may be effected by immersion of the article in a fluid containing or comprising the said agent. In this way fluid enters the article through pores present therein to contact with the binder.
In one aspect of the invention the contact is effected by immersing the article in an aqueous solution of the agent .
The aqueous solution may be heated to facilitate the removal of binder from the article. The temperature of the solution is preferably above the melting point of the binder whereby the binder liquifies when immersed in the solution.
The binder material may be a higher fatty acid. In this case the modification process may comprise hydrolysis of the acid in the presence of an alkaline solution. Thus the salt of the fatty acid is formed, which salt dissolves into solution to effect removal of the binder.
A preferred fatty acid is stearic acid. Fatty acids are cheap, readily available and very effective binder / lubricants. However, their use up to date for high purity applications has been restricted by the difficulty of completely removing the binder after pressing and by their high carbon content which makes residues particularly damaging for certain high purity applications .
In another aspect of the invention the binder may comprise a mixture of the water-insoluble binder material and a water-soluble material. Such a water soluble material may be a long chain alcohol such as a polyethylene glycol . A preferred combination is a fatty acid such as stearic acid and a polyethylene glycol. In some embodiments up to 5% by weight of fatty acid is added to up to 5% by weight of glycol. Polyethylene glycol is a good binder and fatty acid a good lubricant. Together, the two components form a mixture which gives good processability in the formation of the "green" articles.
The aqueous solution may include hydroxide ions introduced by adding an hydroxide which dissociates in water. Typical examples are sodium hydroxide, potassium hydroxide, ammonium hydroxide and the like.
The hydroxide should be added in sufficient proportions to ensure stoichio etric reaction which the binder, whilst retaining low viscosity which permits effective penetration of the article.
The fluid may be stirred or otherwise agitated during the removal process. Alternatively, the article itself may be agitated while immersed thereby enhancing the penetration of fluid into the article. Suitable agitation apparatus will be known to the person skilled in the art.
Once the modification process is complete, any binder derivative remaining in the article may be removed by washing of the article in clean water. The washing process may be repeated to ensure complete removal of modified binder. Where a metal hydroxide solution has been used, the progress and effectiveness of the washing process may be monitored by measuring the conductivity of the of each wash solution; remaining metallic ions in solution will give relatively high conductivity readings .
After washing the article may be dried and then sintered to form a consolidated product.
The particles may be metallic for example niobium, aluminium, tantalum and other anodisable metals. In one embodiment the particles comprise tantalum powder. The article may be configured to be the anode of a capacitor. Such articles range in size from about 0.6mm cubed to cylinders about 6mm in diameter and 7mm long .
The present invention has particular application in the production of tantalum capacitors whereby tantalum powder anodes are formed from sintered tantalum powder and then incorporated into the capacitor. In such products it is essential that all binder or binder residues are removed in order to ensure correct and reliable operation of the capacitor formed, in particular by restricting the formation of a carbonaceous deposit on the anode surface.
Following is a description by way of example only of methods of putting the present invention into effect. Tantalum powder is mixed with a small quantity (5% by weight) of stearic acid (CH3 -[CH2]16 -C00H) binder / lubricant. The mixture is then pressed to form a shaped article, in this example the anode component of a solid state capacitor.
The article is then immersed in 0.5% aqueous sodium hydroxide solution heated to about 80 'C for about 30 minutes to effect reaction. During this time the article is agitated to ensure complete penetration of the article by the solution, and also to ensure that un- reacted solution is continually introduced into the article while reaction products dissolve into the bulk solution .
Once the reaction / dissolution process is complete, the article is removed from the solution and washed in clean water to remove any remaining stearate present in the pores of the article. The washing step may be repeated to ensure complete cleaning. After each step the conductivity of the cleaning solution can be sampled by conventional methods to give an indication of the sodium ion concentration. As the sodium ions are washed away, conductivity of the wash solution decreases until the required cleanliness is achieved. In an alternative embodiment of the present invention the binder comprises a mixture of stearic acid and polyethylene glycol with an average molecular weight of 2000. The acid and glycol are present in weight percentages of 4% and 0.5% respectively (as a percentage of tantalum weight). The rest of the process variables are substantially identical.
The process chemicals used in the methods of the present invention are relatively low hazard, cheap and easily disposable with a low environmental impact.
Tantalum anodes produced in a method according to the present invention are very low in carbon because the carbonaceous materials are, in effect, completely removed. Furthermore, negligible quantities of oxygen are added during the binder removal process due to the low temperatures possible in the removal process of the present invention. Because of this the electrical characteristics of the finished articles are significantly improved. In particular, the reliability of the capacitors is increased and current leakage in use is reduced.

Claims

1. A method of removing water-insoluble binder from a porous article formed from pressed particulate material comprising contacting the article with an aqueous solution of an agent which reacts with said binder to produce a water soluble derivative thereof whereby said binder derivative may be substantially dissolved in said solution.
2. A method as claimed in claim 1 wherein the derivative is produced by hydrolysis.
3. A method as claimed in any one of the preceding claims wherein the binder comprises an acidic material and the solution comprises hydroxide ions.
4. A method as claimed in any preceding claim wherein the binder consists of a fatty acid.
5. A method as claimed in any one of the preceding claims wherein the binder further comprises a water-soluble material.
6. A method as claimed in claim 5 wherein the hydrophilic material is a polyethylene glycol.
7. A method as claimed in any one of the preceding claims wherein the particulate material consists of tantalum powder.
8. A method as claimed in any one of the preceding claims wherein the article is configured to be an electrode of a capacitor.
9. A method of removing water-insoluble binder from a porous article formed from pressed particulate material substantially as hereinbefore described.
PCT/GB1998/000023 1997-01-13 1998-01-06 Binder removal WO1998030348A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
AT98900293T ATE223274T1 (en) 1997-01-13 1998-01-06 REMOVAL OF BINDER
EP98900293A EP0951374B1 (en) 1997-01-13 1998-01-06 Binder removal
DE69807650T DE69807650T2 (en) 1997-01-13 1998-01-06 REMOVAL OF BINDING AGENT
AU54904/98A AU5490498A (en) 1997-01-13 1998-01-06 Binder removal
IL13089298A IL130892A (en) 1997-01-13 1998-01-06 Method of manufacturing a solid state capacitor
KR10-1999-7006307A KR100494140B1 (en) 1997-01-13 1998-01-06 A method of forming an anode body for use in manufacturing a solid state capacitor
JP53062998A JP4230541B2 (en) 1997-01-13 1998-01-06 Binder removal method
US09/351,637 US6197252B1 (en) 1997-01-13 1999-07-12 Binder removal

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9700566.4A GB9700566D0 (en) 1997-01-13 1997-01-13 Binder removal
GB9700566.4 1997-01-13

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US09/351,637 Continuation US6197252B1 (en) 1997-01-13 1999-07-12 Binder removal

Publications (1)

Publication Number Publication Date
WO1998030348A1 true WO1998030348A1 (en) 1998-07-16

Family

ID=10805885

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1998/000023 WO1998030348A1 (en) 1997-01-13 1998-01-06 Binder removal

Country Status (12)

Country Link
US (1) US6197252B1 (en)
EP (1) EP0951374B1 (en)
JP (1) JP4230541B2 (en)
KR (1) KR100494140B1 (en)
CN (1) CN1106898C (en)
AT (1) ATE223274T1 (en)
AU (1) AU5490498A (en)
DE (1) DE69807650T2 (en)
GB (1) GB9700566D0 (en)
IL (1) IL130892A (en)
PT (1) PT951374E (en)
WO (1) WO1998030348A1 (en)

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US6197252B1 (en) 2001-03-06

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