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Aluminium Electrolytic Capacitors: Wound, Soaked and Sealed
Ed

Created by

Ed

11. October 2026FI
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Aluminium Electrolytic Capacitors: Wound, Soaked and Sealed

An aluminium electrolytic capacitor is two aluminium foils wound up with a paper spacer between them. The anode foil is etched rough to multiply its surface and then "formed": a voltage in an electrolytic bath grows an insulating oxide layer whose thickness follows the forming voltage, and that oxide is the dielectric. The liquid electrolyte soaked into the paper, commonly ethylene glycol with boric acid, is the real cathode; the second foil only connects to it. The foils and paper are cut to width, wound with their terminals welded on, soaked with electrolyte under vacuum, put in an aluminium can, sealed with a rubber disc by curling the can's edge, sleeved, and finally run at rated voltage in heat to heal any oxide damaged by cutting and winding.
Advanced
Factory process

Instructions

1

Cut the foils and paper

Cut the etched and formed anode foil, the spacer paper and the cathode foil from their mother rolls to width.

Materials for this step:

Etched and Formed Anode FoilEtched and Formed Anode Foil1 as required
Aluminium FoilAluminium Foil1 as required
Capacitor Spacer PaperCapacitor Spacer Paper1 as required
2

Wind

Weld on the terminals, wind the foils with the paper between them, and cut the winding to length.

Tools needed:

Capacitor Winding MachineCapacitor Winding Machine
3

Impregnate

Soak the winding with electrolyte under vacuum.

Materials for this step:

Ethylene GlycolEthylene Glycol1 as required
Boric AcidBoric Acid1 as required

Tools needed:

Vacuum Impregnation ChamberVacuum Impregnation Chamber
4

Case and seal

Put the winding in the aluminium can, fit the rubber sealing disc and curl the can's edge to seal it; add the insulating sleeve.

Materials for this step:

Aluminium Capacitor CanAluminium Capacitor Can1 piece
Rubber Sealing DiscRubber Sealing Disc1 piece
Heat Shrink TubingHeat Shrink Tubing1 piece
5

Post-form and test

Apply rated voltage at high temperature to heal the oxide, then measure capacitance, leakage current and impedance.

Tools needed:

High-Temperature Post-Forming RackHigh-Temperature Post-Forming Rack

Materials

8

Tools Required

3

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