Solid-Electrolyte Capacitor Manufacturing Device with Uniform Current Control
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Solution Overview
Problem
Conventional methods for producing solid electrolytic capacitors with high capacitance and low ESR face challenges in achieving uniform semiconductor layers due to uneven current distribution and high production costs, particularly in industrial-scale production.
Innovation Solution
A production apparatus with sockets for fixing lead wires and a circuit for uniform current application, allowing for sequential formation of dielectric and semiconductor layers on multiple conductors, enabling continuous and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional chemical formation method is used to form semiconductor layer, then production cost is reduced, but the semiconductor layer has uneven thickness and high resistivity resulting in large ESR
Solution Approach 1:
The patent changes the fundamental parameter of formation method from chemical to electrochemical, enabling precise control of semiconductor layer thickness and composition through electrical parameters (current, voltage, time) while maintaining industrial-scale production capability. The electrochemical method allows independent control of current to each conductor, ensuring uniform layer formation.
Solution Approach 2:
The patent replaces the chemical formation process with an electrochemical process, substituting chemical reactions with controlled electrical reactions. This substitution enables precise control over semiconductor layer properties through electrical parameters while maintaining cost-effectiveness and scalability for industrial production.
2Manufacturing precision
If external electrodes are provided in vicinity of each conductor for electrochemical treatment, then uniform current distribution is achieved, but it is difficult to maintain even intervals in industrial-scale production
Solution Approach 1:
The patent segments the electrical connection system by providing individual sockets for each conductor on the circuit board. This segmentation allows independent current control to each conductor while simplifying the overall electrode arrangement to just two external electrodes (anode and cathode), eliminating the complexity of positioning multiple external electrodes at even intervals.
Solution Approach 2:
The patent introduces a circuit board with individual sockets as an intermediary between the external electrodes and conductors. This intermediary device distributes current uniformly to each conductor through dedicated electrical pathways, eliminating the need for complex external electrode positioning while maintaining current distribution uniformity.
3Productivity
If metal long plate is used as anode for electrochemical formation, then production efficiency is improved, but current distribution among multiple conductors becomes uneven
Solution Approach 1:
The patent introduces a circuit board with individual sockets as an intermediary between the anode and conductors. This intermediary distributes current uniformly to each conductor through dedicated electrical pathways, eliminating the current distribution problems associated with direct metal plate contact while maintaining high production efficiency through batch processing.
Solution Approach 2:
The patent applies local quality control by providing individual electrical pathways (sockets) for each conductor on the circuit board. This allows tailored current distribution to each conductor position, ensuring uniform current density across all conductors while maintaining the efficiency of batch electrochemical processing.
4Ease of manufacture
If conductors are soldered to metal plate and then processed, then production cost is reduced, but removal of capacitors requires heating or stress that may damage soldering
Solution Approach 1:
The patent employs a disposable or reusable circuit board with sockets that facilitates easy capacitor removal without damaging soldering. The socket design allows capacitors to be inserted and removed through simple mechanical actions rather than requiring heating or stress, preserving soldering integrity while maintaining cost-effectiveness through the reusable nature of the circuit board.
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
This approach results in capacitors with narrow capacitance variation and low ESR, facilitating efficient and stable mass production by ensuring uniform current distribution and reducing production costs.
Implementation Method 1
electric current is passed, to thereby form a dielectric layer
Implementation Method 2
electric current is passed to thereby electrochemically laminate a semiconductor layer on the dielectric layer
Data Source
AI summary
The invention provides an apparatus for producing solid electrolytic capacitors having uniform properties with excellent ESR value efficiently at low costs and a production process using the apparatus. The production process using the apparatus is characterized in that a plurality of conductors for producing solid electrolytic capacitors are fixed to a jig for producing capacitors, the jig is transferred to above treatment baths to immerse the conductors in treatment solution in each of the baths sequentially and electric currents are passed to the conductors therein to thereby form a dielectric layer and a semiconductor layer sequentially on the conductors and that on the jig for producing capacitors, a plurality of sockets are provided for inserting and fixing ends of wires leading out of the conductors by using a robotics device.