cathode

11 Articles

Learning About Capacitors By Rolling Your Own Electrolytics

October 24, 2023 by 17 Comments

Ever wonder what’s inside an electrolytic capacitor? Many of us don’t, having had at least a partial glimpse inside after failure of the cap due to old age or crossed polarity. The rest of us will have to rely on this behind-the-scenes demo to find out what’s inside those little aluminum cans.

Perhaps unsurprisingly, it’s more aluminum, at least for the electrolytics [Denki Otaku] rolled himself at the Nippon Chemi-Con R&D labs. Interestingly, both the anode and cathode start as identical strips of aluminum foil preprocessed with proprietary solutions to remove any oils and existing oxide layers. The strips then undergo electrolytic acid etching to create pits to greatly increase their surface area. The anode strips then get anodized in a solution of ammonium adipate, an organic acid that creates a thin aluminum oxide layer on the strip. It’s this oxide layer that actually acts as the dielectric in electrolytic capacitors, not the paper separator between the anode and cathode strips.

Winding the foils together with the paper separator is pretty straightforward, but there are some neat tricks even at the non-production level demonstrated here. Attachment of lead wires to the foil is through a punch and crimp operation, and winding the paper-foil sandwich is actually quite fussy, at least when done manually. No details are given on the composition of the electrolyte other than it contains a solvent and an organic acid. [Denki] took this as an invitation to bring along his own electrolyte: a bottle of Coke. The little jelly rolls get impregnated with electrolyte under vacuum, put into aluminum cans, crimped closed, and covered with a heat-shrink sleeve. Under test, [Denki]’s hand-rolled caps performed very well. Even the Coke-filled caps more or less hit the spec on capacitance; sadly, their ESR was way out of whack compared to the conventional electrolyte.

There are plenty more details in the video below, although you’ll have to pardon the AI voiceover as it tries to decide how to say words like “anode” and “dielectric”; it’s a small price to pay for such an interesting video. It’s a much-appreciated look at an area of the industry that few of us get to see in detail.

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Rock Salt May Lead The Way To Better Batteries

October 5, 2023 by 58 Comments

The regular refrain here when it comes to announcements of new battery chemistries hailed as potentially miraculous is that if we had a pound, dollar, or Euro for each one we’ve heard, by now we’d be millionaires. But still they keep coming, and it’s inevitable that there will one or two that break through the practicality barrier and really do deliver on their promise. Which brings us tot he story which has come our way today, the suggestion that something as simple as rock salt could triple the energy density of a lithium-ion vehicle battery.

The research led from Lawrence Berkeley National Laboratory started around the use of cobalt in the battery cathode, an expensive and finite resource with the added concern of being in large part a conflict mineral from the Democratic Republic of Congo. Cobalt is used in  the cathodes because its oxide crystals form a stable layered structure into which the lithium ions can percolate. Alternative layered-structure metal oxides perform less well in retaining the lithium ions, making them unsuccessful substitutes. It seems that the three-dimensional structure of a rock salt crystal performs up to three times better than any layered oxide, which is where the excitement comes from.

Of course, if it were that simple we’d all be using three-times-more-powerful, half-price 18650s right now, which of course we aren’t. The challenge comes in making a rock salt cathode which both holds the lithium ions, and keeps that property reliably over the thousands of charge cycles needed for a real-world application. This one may yet be anther dollar on that metaphorical pile, but it just might give us the batteries we’ve been looking for.

Then again, when you’re looking at exciting battery chemistry, why limit yourself to lithium?

A Loving Look Inside Vacuum Fluorescent Displays

February 26, 2023 by 20 Comments

Everyone knows we’re big fans of displays that differ from the plain old flat-panel LCDs that seem to adorn most devices these days. It’s a bit boring when the front panel of your widget is the same thing you stare at hour after hour while using your phone. Give us the chunky, blocky goodness of a vacuum fluorescent display (VFD) any day of the week for visual interest and retro appeal.

From the video below, it seems like [Posy] certainly is in the VFD fandom too, rolling out as he does example after example of unique and complicated displays, mostly from audio equipment that had its heyday in the 1990s. In some ways, the video is just a love letter to the VFD, and that’s just fine with us. But the teardowns do provide some insights into how VFDs work, as well as suggest ways to tweak the overall look of a VFD.

For example, consider the classy white VFDs that graced a lot of home audio gear back in the day. It turns out, the phosphors used in those displays weren’t white, but closer to the blue-green color that VFDs are often associated with. But put a pink filter between the display and the world, and suddenly those turquoise phosphors look white. [Posy] does a lot of fiddling with the stock filters to change the look of his VFDs, some to good effect, others less so.

As for the internals of VFDs, [Posy]’s look at a damaged display reveals a lot about how they work. With a loose scrap of conductor shorting one of the cathodes inside the tube, the damaged VFD isn’t much to look at, and is beyond reasonable repair, but it’s kind of cool to examine the spring mechanisms that take up slack as the cathodes heat up and expand.

Thanks to [Posy] for this heartfelt look into the VFDs of yesterday. If you need more about how VFDs work, we’ve covered that before, too.

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A Homemade Tube Amplifier Featuring Homemade Tubes

October 27, 2022 by 23 Comments

With the wealth of cheap and highly integrated audio amplifier modules on the market today, it takes a special dedication to roll your own from parts. Especially when those parts include vacuum tubes, and doubly so when you make the vacuum tubes from scratch too.

Now, we get it — some readers are going to find it hard to invest an hour in watching [jdflyback] make a pair of triodes to build his amplifier. But really, you’ve got to check this out. Making vacuum tubes with all the proper equipment — glassblower’s lathe, various kinds of oxy-fuel torches, all the right hand tools — is hard enough. But when your lathe is a cordless drill, and you’re using a spot welder that looks like it’s cobbled together from junk, your tube-making game gets a lot harder. Given all that, you’d expect the tubes to look a lot rougher than they are, but even with plain tungsten wire heaters and grids made from thick copper wire, they actually work pretty well. Sure, the heaters glow as bright as light bulbs, but that’s all part of the charm.

Speaking of charm, we just love the amp these tubes went into. Built in 1920s breadboard-style, the features some beautiful vintage mica capacitors and wirewound resistors, plus a variable resistor the likes of which we’ve never seen. The one nod to modernity is the clever use of doorbell transformers, one for a choke and one for the speaker transformer. They don’t sound great, but there’s no doubt they work.

We may have seen other homemade vacuum tubes before — we even recently featured a DIY X-ray tube — but there’s something about [jdflyback]’s tubes that really gets us going.

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3D-Printed Tooling Enables DIY Electrochemical Machining

July 29, 2021 by 10 Comments

When it comes to turning a raw block of metal into a useful part, most processes are pretty dramatic. Sharp and tough tools are slammed into raw stock to remove tiny bits at a time, releasing the part trapped within. It doesn’t always have to be quite so violent though, as these experiments in electrochemical machining suggest.

Electrochemical machining, or ECM, is not to be confused with electrical discharge machining, or EDM. While similar, ECM is a much tamer process. Where EDM relies on a powerful electric arc between the tool and the work to erode material in a dielectric fluid, ECM is much more like electrolysis in reverse. In ECM, a workpiece and custom tool are placed in an electrolyte bath and wired to a power source; the workpiece is the anode while the tool is the cathode, and the flow of charged electrolyte through the tool ionizes the workpiece, slowly eroding it.

The trick — and expense — of ECM is generally in making the tooling, which can be extremely complicated. For his experiments, [Amos] took the shortcut of 3D-printing his tool — he chose [Suzanne] the Blender monkey — and then copper plating it, to make it conductive. Attached to the remains of a RepRap for Z-axis control and kitted out with tanks and pumps to keep the electrolyte flowing, the rig worked surprisingly well, leaving a recognizably simian faceprint on a block of steel.

[Amos] admits the setup is far from optimized; the loop controlling the distance between workpiece and tool isn’t closed yet, for instance. Still, for initial experiments, the results are very encouraging, and we like the idea of 3D-printing tools for this process. Given his previous success straightening his own teeth or 3D-printing glass, we expect he’ll get this fully sorted soon enough.

Overdriving Vacuum Tubes And Releasing The Magic Light Within

July 15, 2021 by 53 Comments

We’ve all seen electronic components that have been coaxed into releasing their small amount of Magic Smoke, which of course is what makes the thing work in the first place. But back in the old times, parts were made of glass and metal and were much tougher — you could do almost anything to them and they wouldn’t release the Magic Smoke. It was very boring.

Unless you knew the secret of “red plating”, of course, which [David Lovett] explores in the video below. We’ve been following [David]’s work with vacuum tubes, the aforementioned essentially smokeless components that he’s putting to use to build a simple one-bit microprocessor. His circuits tend to drive tubes rather gently, but in a fun twist, he let his destructive side out for a bit and really pushed a few tubes to see what happens. And what happens is pretty dramatic — when enough electrons stream from the cathode to the anode, their collective kinetic energy heats the plate up to a cherry-red, hence the term “red plating”.

[David] selected a number of victims for his torture chamber, not all of which cooperated despite the roughly 195 volts applied to the plate. Some of the tubes, though, cooperated in spades, quickly taking on a very unhealthy glow. One tube, a 6BZ7 dual triode, really put on a show, with something getting so hot inside the tube as to warp and short together, leading to some impressive pyrotechnics. Think of it as releasing the Magic Light instead of the Magic Smoke.

Having seen how X-ray tubes work, we can’t help but wonder if [David] was getting a little bit more than he bargained for when he made this snuff film. Probably not — the energies involved with medical X-ray tubes are much higher than this — but still, it might be interesting to see what kinds of unintended emissions red-plating generates.

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State Of The Art For Nixies Gets A Boost From Dalibor Farny’s Supersize Prototype

September 28, 2020 by 14 Comments

Never one to pass up on a challenge, artisanal Nixie tube maker [Dalibor Farný] has been undertaking what he calls “Project H”, an enormous array of 121 Nixie tubes for an unnamed client. What’s so special about that? Did we mention that each Nixie is about the size of a sandwich plate?

Actually, we did, back in May when we first noted Project H in our weekly links roundup. At that time [Dalibor] had only just accepted the project, knowing that it would require inventing everything about these outsized Nixies from scratch. At 150 mm in diameter, these will be the largest Nixies ever made. The design of the tube is evocative of the old iconoscope tubes from early television history, or perhaps the CRT from an old oscilloscope.

Since May, [Dalibor] has done most of the design work and worked out the bugs in a lot of the internal components. But as the video below shows, he still has some way to go. Everything about his normal construction process had to be scaled up, so many steps, like the chemical treatment of the anode cup, are somewhat awkward. He also discovered that mounting holes in the cathodes were not the correct diameter, requiring some clench-worthy manual corrections. The work at the glassblower’s lathe was as nerve wracking as it was fascinating; every step of the build appears fraught with some kind of peril.

Sadly, this prototype failed to come together — a crack developed in the glass face of the tube. But ever the pro, [Dalibor] took it in stride and will learn from this attempt. Given that he’s reduced the art of the Nixie to practice, we’re confident these big tubes will come together eventually.

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