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Aluminum Electrolytic Capacitor
Anode Foil
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Manufacturing Process  
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  Vertically Integrated Production Chain

 
Production Process
The production process involves 3 stages, namely the production of anode etched foils, anode formed foils and aluminum electrolytic capacitors.
Anode Foils
Stage Ⅰ:The Etching Process
The etching process is fully automated and is summarised in the diagram below:

 
Process Description & Explanation
(1)Aluminum Foil Aluminum foil will be fixed onto a plastic roller to be rolled into the production machine, using low quality aluminum foil attached at the beginning of the roller to smoothen the rolling process.
(2)StabilisingThe aluminum foil will be attached to the plastic roller tightly after rolling through a set of patterned roller.
(3)Current ApplyingCurrent will be applied through this point for etching.
(4)Pre-treatment WashingThe aluminum foil will pass through the first pretreatment washing trough to cleanse the aluminum foil with water.
(5)Stage I etching Forming tunnel pits in aluminum foil through electrolysis by applying a voltage to the aluminum foil in an etching solution (sulphuric acid). Different characteristics of foil will be determined by applying different voltages under different temperatures.
(6)Washing Cleansing off the acid remaining on the surface of aluminum foil during stage I etching with pure water by passing through the second washing trough.
(7)Stage II etching Enlarging the diameter of the tunnel pits formed in stage I etching process thus increasing the surface area of aluminum foil through electrolysis by applying a voltage to the aluminum foil in an etching solution (sulphuric acid). Different characteristics of foil will be determined by applying different voltages under different temperatures.
(8)Washing Cleansing off the acid remaining on the surface of aluminum foil during stage II etching with pure water by passing through the third washing trough.
(9)Chemical RinsingA chemical rinsing process to remove Cl- ion from the foil surface with acid.
(10)After-treatment WashingThe foil is further cleansed with water to remove leftover chemical substances from the foil surface by passing through the last washing trough.
(11)Drying Any water left on the etched foil surface is vaporized in this heat treatment process through the drying heater.
(12)Stabilising The aluminum foil will be attached to the plastic roller tightly after rolling through a set of patterned roller.
(13)Etched Foil The anode etched foil will be rolled back for packaging.
The etching process is very sensitive to environmental changes and the quality of anode etched foils may be affected by even slight changes in temperature or voltage. Hence, the whole etching process is being inspected by research and development staff a few times each day. General quality control processes including IQC, PQC and OQC are also adopted.
 
 
Stage Ⅱ:The Forming Process
The forming process is fully automated and is summarised in the diagram below::