Aluminum Foil 1235 6 Microns for Capacitor Foil
Introduction
Aluminum Foil 1235 with a thickness of 6 microns is a high-quality, ultra-thin aluminum alloy foil specifically designed for use in capacitor manufacturing. Renowned for its excellent electrical conductivity, corrosion resistance, and mechanical strength, this foil provides superior reliability and performance in electrical applications.
Working with Aluminum Foil 1235 6 Microns for capacitor foil presents a unique set of challenges compared to other aluminum foil applications. The incredibly tight tolerance on thickness (6 microns is exceptionally thin!) demands meticulous control throughout the entire production process, from initial casting to final inspection. We constantly monitor the rolling mill's settings, paying close attention to roll pressure, temperature, and lubrication to ensure consistent gauge. Any slight deviation can lead to significant defects that render the foil unusable for high-precision capacitors. The surface quality is equally critical; even microscopic imperfections can impact the dielectric properties of the finished capacitor. We use advanced surface analysis techniques to identify and address potential issues before they affect a large batch.
The 1235 alloy itself is carefully selected for its electrical conductivity and corrosion resistance. While it's a relatively standard alloy, achieving the required purity and consistency for capacitor applications is crucial. We've seen firsthand how seemingly minor variations in the alloy's composition can affect the foil's electrochemical properties, leading to reduced capacitor lifespan or performance issues. This demands rigorous quality control at every stage of the supply chain, from the raw material sourcing to the final packaging. The slightest contamination can be disastrous, highlighting the precision and care needed when handling this specialized material. Ultimately, the success of our capacitor foil hinges on the mastery of these subtle details.
Alloy Overview: 1235 Aluminum Foil
The 1235 alloy is part of the commercially pure aluminum 1xxx series, which primarily consists of aluminum content greater than 99.3%. The features of this alloy are high electrical and thermal conductivity, excellent corrosion resistance, and good flexibility. Its highly pure composition makes it an ideal choice for electrical use such as capacitor foil.
Chemical Composition
| Element | Typical Content (%) | Standard Range (%) (ASTM B479) |
|---|---|---|
| Aluminum (Al) | 99.35 - 99.70 | 99.30 - 99.80 |
| Copper (Cu) | ≤ 0.05 | 0.00 - 0.05 |
| Iron (Fe) | ≤ 0.40 | 0.00 - 0.40 |
| Silicon (Si) | ≤ 0.25 | 0.00 - 0.25 |
| Zinc (Zn) | ≤ 0.10 | 0.00 - 0.10 |
| Titanium (Ti) | ≤ 0.03 | 0.00 - 0.03 |
| Others | ≤ 0.15 | 0.00 - 0.15 |
Physical and Mechanical Properties
| Property | Parameter | Value | Units |
|---|---|---|---|
| Density | 2.70 | g/cm³ | |
| Electrical Conductivity | ≥ 59 | % IACS | |
| Tensile Strength | 90 - 130 | MPa | |
| Elongation | ≥ 2 | % | |
| Hardness (Hv) | 25 - 40 | Vickers Hardness | |
| Thickness | 6 | Microns (μm) | |
| Thermal Conductivity | ~235 | W/m·K |
Features of Aluminum Foil 1235 6 Microns
1. Ultra-Thin Gauge with High Uniformity
At only 6 microns thickness, this foil delivers ultra-thin dimensions with exceptional thickness uniformity, critical for capacitor foil to ensure consistent electrical properties and minimal variation in dielectric strength of the capacitor assembly.
2. Superior Electrical Conductivity
Thanks to its high aluminum purity and 1xxx alloy series classification, the 1235 foil provides excellent electrical conductivity which is essential for minimizing resistive losses and enhancing capacitor efficiency.
3. Outstanding Corrosion Resistance
The alloy's natural ability to resist oxidation and environmental corrosion contributes to the long lifespan and electrical integrity of capacitor elements, particularly in challenging operating environments.
4. Good Mechanical Strength and Flexibility
Even at very thin gauges, the 1235 foil maintains good tensile strength and elongation, allowing it to be processed into convoluted or wound shapes without causing foil cracking or failure.
5. Surface Finish and Cleanliness
The foil is specially processed to ensure a smooth surface finish and low inclusions, preventing any impurities which may lead to electrical short circuits within the capacitor.
Applications in Capacitors
Aluminum foil of the 1235 alloy at 6 microns is widely used in the manufacturing of electrolytic capacitors due to these properties:
- Anode Foil: Acts as the anode current collector with high surface area and uniform thickness, supporting the oxide dielectric layer formation.
- Cathode Foil: Serves as the cathode with superior conductivity and mechanical flexibility.
- Roll Wound and Stacked Capacitors: Used for both types of capacitor winding techniques, ensuring precise assembly and electrical performance.
- Film Capacitors: Application in thin film capacitors needing ultra-thin foils to achieve specific energy storage capabilities and miniaturization.
Other Related Applications
Besides capacitors, ultra-thin 1235 aluminum foil is sometimes used in transformer winding, high-frequency inductors, and thin-layer packaging where electrical conductivity, thin dimensions, and mechanical resilience are also required.
Quality Standards and Production
Our Aluminum Foil 1235 6 Microns undergoes stringent quality control in line with international standards such as ASTM B479 / ASM D2102, ensuring consistent thickness, mechanical properties, and electrical conductivity required by capacitor manufacturers worldwide. Surface purity inspection and straightness tests are performed at every batch to guarantee superior product reliability.
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