Electrolytic Capacitor Cathode Welding With High-Friction Carbon Layer
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Solution Overview
Problem
The connectivity between the cathode body with a carbon layer and the lead terminal in electrolytic capacitors is poor due to lower physical connection strength and higher electrical resistance, especially when connected via cold pressure welding.
Innovation Solution
The electrolytic capacitor design includes a cathode body with a carbon layer having a maximum static friction coefficient of 0.6 or more, and a cold pressure welding process that uses a pressing component with a trapezoidal shape, ensuring the carbon layer is caught by the cathode foil during welding, reducing stress concentration and improving connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a carbon layer is formed on the cathode foil to increase cathode-side capacitance, then the cathode-side capacitance is improved, but the physical connection strength between the cathode body and lead terminal deteriorates
Solution Approach 1:
The patent changes the friction coefficient parameter of the carbon layer surface to 0.6 or more through surface treatment or material selection. This parameter change allows the carbon layer to maintain high cathode-side capacitance while providing sufficient friction for strong physical connection during cold pressure welding with the lead terminal.
2Quantity of substance
If a carbon layer is formed on the cathode foil to increase cathode-side capacitance, then the cathode-side capacitance is improved, but the electrical resistance between the cathode body and lead terminal increases
Solution Approach 1:
The patent optimizes the friction coefficient parameter of the carbon layer to 0.6 or more, which creates sufficient mechanical interlocking during cold pressure welding. This ensures both low electrical resistance through good electrical contact and high cathode-side capacitance through the carbon layer's inherent properties.
3Ease of manufacture
If cold pressure welding is used to connect the cathode body with carbon layer to the lead terminal, then the manufacturing process is simplified, but the connectivity between cathode body and lead terminal deteriorates
Solution Approach 1:
The patent modifies the carbon layer surface friction coefficient to 0.6 or more, which enables cold pressure welding to achieve both simplified manufacturing and improved connectivity. The increased friction ensures adequate mechanical interlocking and electrical contact during the cold pressure welding process, resolving the contradiction between ease of manufacture and connectivity reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved design enhances the physical connection strength and reduces electrical resistance between the cathode body and the lead terminal, resulting in better connectivity and stability.
Implementation Method 1
a maximum static friction coefficient of a surface of the carbon layer (32) of the cathode body (3) is 0.6 or more
Implementation Method 2
the anode body, the cathode body, and the flat portion of the lead terminal are laminated and are pressurized in the lamination direction under non-heating condition. It is said that this causes atomic boding between each of the anode body and the cathode body, and the flat portion of the lead terminal.
Data Source
AI summary
An electrolytic capacitor with improved connectivity between a cathode body including a carbon layer and a lead terminal, and a production method thereof are provided. The electrolytic capacitor 1 includes an anode body 2 having a dielectric oxide film 5 on a surface thereof, a cathode body 3 having a cathode foil 31 and a carbon layer 32 formed on the cathode foil 31, electrolytic solution 6 interposed between the anode body 2 and the cathode body 3, and a lead terminal 7 connected to each of the anode body 2 and the cathode body 3 by cold pressure welding. A maximum static friction coefficient of a surface of the carbon layer of the cathode body is 0.6 or more.