Electrodes of sintered tantalum powder of fine grain size and process of production

Claim 2

An electrode having an electrical capacitance in excess of 10,000 μC/g prepared by sintering tantalum powder having a grain size finer than 2.5 μm.

Claim 3

A process for preparing an electrode according to claim 1, which comprises sintering tantalum powder having a grain size finer than about 2.5 μm.

Claim 4

A process according to claim 2 wherein said powder is sintered for about 1 minute to 1 hour at about 1,600° C.

Claim 5

The electrode of claim 1 wherein said tantalum powder having a grain size finer than 2.5 μm is produced by a continuous process which comprises heating a shallow bed of a powdered alkali metal tantalum halide in a vacuum and/or under an inert atmosphere thereby removing any water and hydrogen halide present at a temperature of about 325° C. up to the sintering point of said powder to such an extent that said heating decrepitates said alkali metal tantalum halide, mixing said powder maintained under a dry inert gas with dry powdered anhydrous alkali metal halide maintained under a dry inert gas and an alkali metal maintained under a dry inert gas in 1:0.75-2.0:4.75-5.5 molar ratio at a temperature above the melting point of said metal and below the ignition point of said mixture thereby forming an extrudable paste, extruding said paste into shaped masses in open containers, the dimension of said shaped masses of paste in said open containers and their temperature at ignition of below 50° C. being predetermined so that the maximum temperature reached by said shaped masses during said reaction is less than about 800° C. and is between about three and five times the ignition temperature of the paste, conveying said shaped masses in open containers therefor through a continuous reaction chamber having an inert atmosphere and a cooling section, an ignition section, a combustion section and another cooling section, cooling said shaped masses in said containers in said cooling section to a temperature below 50° C., igniting said shaped masses in said container in said ignition section by contacting said shaped masses at a single point with a glowing external ignitor, allowing the combustion which occurs to proceed to completion in said combustion section in the absence of external application of heat, cooling said reacted shaped masses in said cooling section to below 50° C., discharging said containers from said reaction chamber, removing the reaction product from said containers, recycling said containers, and removing any alkali metal halide and alkali metal present in said reaction product, said reaction mixture being maintained under an inert atmosphere at least until said reaction is substantially complete.