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AssigneeFurukawa-Sky Aluminum Corp.
InventorsOsamu Kato, Toshiki Maezono, Masatsugu Saito
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A resin-coated aluminum alloy sheet material for an aluminum electrolytic capacitor case includes a resin layer that contains wax composed of at least one of polyethylene wax and carnauba wax, and has a thickness falling within a range from at least 2 μm to at most 22 μm. A total of lengths of wax particles, defined when the wax particles are cut along a straight line of 100 μm optionally drawn on the surface of the resin layer, is at least 10 μm. A number of the wax particles, featured by a cross-sectional shape having a size of at most 80% of the thickness of the resin layer and of at least 0.1 μm, is from at least 3 to at most 50. A number of the wax particles, featured by a cross-sectional shape featured by a major axis extent having a size of more than 80% of the thickness of the resin layer is less than 10.
A resin-coated aluminum alloy sheet material for an aluminum electrolytic capacitor case, comprising a resin layer composed of either an epoxy-based resin or a polyester-based resin and containing wax composed of at least one of polyethylene wax and carnauba wax, wherein:
Dependencies are inferred from the claim text.
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Coating compositions based on polyesters obtained by reactions forming a carboxylic ester
Nitrogen containing compounds: ureas; Thioureas; Guanidines; Dicyandiamides
Not modified by chemical after-treatment: homopolymers or copolymers of ethene
Coating compositions based on epoxy resins
About 2 years 4 months of term left · ends 28 Feb 2029 (estimated)
The present invention relates to a resin-coated aluminum alloy sheet material featuring superior formability to a deep drawing and ironing, and more particularly, relates to such a resin-coated aluminum alloy sheet material useful to a case for an aluminum electrolytic capacitor, such an aluminum electrolytic capacitor case, and such an aluminum electrolytic capacitor.
Recently, a resin-coated aluminum alloy sheet material, which does not need an insulative resin-coating process after a formation process, is used as a material for an aluminum electrolytic capacitor case. Due to the fact that this aluminum electrolytic capacitor case material is subjected to a severe formation process including a combination of a deep drawing and an ironing, if a usual resin-coated aluminum alloy sheet material for buildings or the like is used instead, cracks, peelings and so forth occur in the resin layer thereof, and thus a sufficient insulative property can not be ensured. Also, a formation process using a volatile press oil, which does not need a solvent degreasing process, prevails in order to obey the recent regulation of solvent, and thus requires a higher formability in comparison with a conventional formation process using a high viscosity oil.
On the other hand, it is well known that addition of a solid lubricant such as wax is effective in improving a formability of a resin-coated aluminum alloy sheet material. In a case where a resin layer is formed by a coating process, when wax is added to a coating material, a part (or all) of the wax cures in the state of existing on a surface of the resin layer due to the fact that the wax generally features a smaller surface energy than that of a base resin as a main component of the resin layer. When the resin-coated aluminum alloy sheet material so produced is subjected to a press formation process, the wax existing on the surface of the resin layer acts as a lubricant, and thus a press tool can smoothly slide on the surface of the resin layer so that cracks or peelings can not easily occur in the resin layer during the press formation process.
FIG. 1 is a typical view visually illustrating a wax-existing state of a variety of wax particles 2a to 2d in an interior of a resin layer 1.
FIG. 2 is an explanatory view illustrating relationships among a variation of temperature, a wax-melting process and a resin-curing temperature during a baling process for a coating material in the course of production of a resin-coated aluminum alloy sheet material for an aluminum electrolytic capacitor case according to the present invention.
1 . . . Resin Layer
2 . . . Wax Particles
5 . . . Straight Line Extent of 100 μm