Abstract:
An electrolyte for an AC motor-start electrolytic capacitor consists essentially of 10 to 40 wt % mono(diethylammonium) or mono(triethylammonium) adipate as solute in ethylene glycol as solvent.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to an AC electrolytic capacitor and more particularly to an electrolyte for an aluminum AC capacitor that has good temperature stability and long life. 
     Aluminum electrolytic capacitors generally have at least a pair of aluminum foil electrodes, one of these having a dielectric oxide formed on its surface, spacer material, a container with an end seal, and an electrolyte. The foil electrodes may be etched to increase the surface area of the foil. The foils are usually separated by dielectric spacer materials such as paper, plastic film, or combinations of these. The foils and spacers may be convolutely wound into a roll that is impregnated with electrolyte before being placed in the container and sealed. 
     Aluminum electrolytic capacitor electrolytes conventionally have an ionizable compound dissolved in a solvent, the commonest being the borate-glycol system. Other electrolytes are formulated with glycol ethers, organic alcohols, and amides as solvents with organic acids, at least partially neutralized, as ionogens. 
     Those aluminum electrolytic capacitors that find use as AC motor-start capacitors are subjected to elevated temperatures of 100° C. or more and to heavy-duty cycling, e.g., frequent starting with high voltage and current conditions. A frequent failure mode of this type of service is that of the electrolytic breaking down under the high temperature conditions. As is pointed out by Anderson in U.S. Pat. No. 4,024,442, glycol ether-based electrolytes have a boiling point that is too low for most AC motor-start applications and the use of such electrolytes may cause catastrophic failure of the capacitor at elevated temperatures. Also, glycol ether-based electrolytes tend to dissolve the potting compounds used to secure the foil roll to the container to prevent movement relative to the container. Since these ethers are good solvents, they may also attack the container and/or seal itself, particularly if either is a phenolic material. Ethylene glycol is being used as a solvent for AC electrolytic capacitors electrolytes now for these and other reasons. 
     SUMMARY OF THE INVENTION 
     It is an object of this invention to provide an improved ethylene glycol-based electrolyte for an aluminum AC electrolytic capacitor, particularly of the motor-start type. 
     It is another object of this invention to provide such an electrolyte having good temperature characteristics, stability, and long operating life together with a desirable resistivity. 
     These objects are attained by the use of an electrolyte consisting essentially of ethylene glycol (which may contain some water) and mono-diethylammonium or mono-triethylammonium adipate as solute. The solute may be prepared by reacting diethylamine or triethylamine with adipic acid in ethylene glycol. Since, preferably, the solute is prepared in the solvent, it should be understood that impurities in the starting materials and minor amounts of unreacted starting materials or other products may be present. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The mono-diethyl or triethyl ammonium adipate is used as sole solute in an ethylene glycol-based electrolyte for an AC capacitor, particularly a motor start capacitor. A minor amount of water may be included to adjust resistivity to the desired level. 
    
    
     The following examples are presented to show the usefulness of such compositions. 
     EXAMPLE I 
     The resistivities of various solutions of monodiethylammonium adipate and mono-triethylammonium adipate in ethylene glycol are given in Tables 1 and 2, respectively. All percentages are weight-percent. Temperature-resistivity characteristics of the diethylammonium adipate electrolyte are compared to those of a conventional borate-glycol electrolyte in Table 3. 
     
                       TABLE I______________________________________           % by weight______________________________________Monodiethylammonium adipate            40     30     20   10    5Ethylene glycol  57     67     77   87    92Water             3      3      3    3    3Resistivity (Ω - cm, 25° C.)            526    490    541  787  1307______________________________________ 
    
     
                       TABLE II______________________________________            % by weight______________________________________Monotriethylammonium adipate             40     30     20    10    5Ethylene glycol   57     67     77    87   92Water              3      3      3     3    3Resistivity (Ω - cm, 25° C.)             683    650    707  1039 1723______________________________________ 
    
     
                                           TABLE III__________________________________________________________________________    Resistivity in Ω - cm at    -40° C.         -30° C.              -20° C.                   0° C.                      25° C.                          50° C.                              85° C.                                  105° C.__________________________________________________________________________Borate-glycol   &gt;300,000         78,000              30,000                   5600                      1150                          400 125 80Diethylammoniumadipate    35,000         13,000               5,900                   1600                       495                          210  88 65__________________________________________________________________________ 
    
     EXAMPLE II 
     This example shows life test results for AC-motor start, 110 VAC capacitors made with a conventional electrolyte (ammonium pentaborate in ethylene glycol) vs 24% mono-diethylammonium adipate in ethylene glycol. The resistivity of this electrolyte was 475Ω-cm. The test was run for 556 hr, 60 1-sec starts/hr. Standard and experimental design capacitors made with 160 V and 170 V aluminum foil were tested. The numbers in parentheses give the number of each type of unit tested at 115 VAC, 60 Hz, and 65° C.; the results presented are an average of these units. 
     
                                           TABLE IV__________________________________________________________________________                        Power Factor           Amps               Watts                   Cap (μF)                        (%)__________________________________________________________________________Conventional electrolyte160V experimental design (6)           5.9 49  136.1                        7.2160V standard design (3)           6.1 69  140.3                        9.9170V experimental design (7)           6.2 75  140.7                        10.7170V standard design (5)           6.1 78  141.2                        11.0Mono-diethylammonium adipateelectrolyte160V experimental design (7)           5.8 35  132.9                        5.3160V standard design (3)           6.0 53  138.4                        7.5170 experimental design (8)           6.0 64  139.6                        9.2170V standard design (2)           6.3 72  144.2                        10.0__________________________________________________________________________ 
    
     EXAMPLE III 
     This example shows the results of life tests as described in Example 2 but run for 833 hrs with experimental design capacitors using 24% mono-triethylammonium adipate electrolyte. 
     
                                           TABLE V__________________________________________________________________________                        Power Factor           Amps               Watts                   Cap (μF)                        (%)__________________________________________________________________________Conventional electrolyte160V experimental (12)           5.7 48  130  7.4170V experimental (12)           6.0 44  138  6.4Mono-triethylammonium adipate160V experimental (16)           5.8 45  133  5.5170V experimental (16)           5.8 36  137  5.3__________________________________________________________________________ 
    
     The results show the improvement in power factor in capacitors using the electrolytes of the present invention.