Electrolytic Capacitor Stacking With Optical Alignment and Burr-Free Foils
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Solution Overview
Problem
Existing methods for manufacturing electrolytic capacitors face challenges in achieving precise stacking and alignment of components, leading to reduced energy density and increased risk of internal short circuits due to metallic particles in paper separators, which can be fatal in medical devices.
Innovation Solution
A method involving optical measurement and gripper-assisted precise positioning of components, use of self-adhesive films for fixing, laser-cut burr-free foils, and double-layer paper separators to ensure accurate stacking and reduce the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are stacked over pins for alignment, then alignment is achieved, but component damage occurs and positioning accuracy is reduced due to required gaps
Solution Approach 1:
The patent replaces the mechanical pin-based alignment system with an optical measurement and active correction system. Optical sensors detect component positions, and actuators adjust component positions to achieve precise alignment without physical contact, thereby avoiding component damage while maintaining high positioning accuracy.
Solution Approach 2:
The patent introduces optical sensors and actuators as intermediary elements between the components and the alignment process. These intermediaries enable non-contact measurement and adjustment, eliminating the need for direct mechanical contact that causes damage while achieving the required alignment precision.
2Measurement precision
If optical edge detection is used for alignment, then position determination is achieved, but inaccuracies occur due to burrs, fraying, and component symmetries
Solution Approach 1:
The patent uses optical sensors to create a digital representation or copy of the component edges and positions. This optical copy is then processed through image recognition algorithms that can identify and correct for imperfections like burrs and fraying, enabling accurate position determination despite manufacturing imperfections in the physical components.
Solution Approach 2:
The patent implements a feedback loop where optical sensors continuously monitor component positions, compare them against target positions, and provide correction signals to actuators. This closed-loop system compensates for measurement inaccuracies caused by edge imperfections and achieves the required positioning precision.
3Measurement precision
If high magnification is used in optical detection, then edge detection accuracy improves, but the detected field of view becomes too small
Solution Approach 1:
The patent divides the detection task into multiple segments by using multiple optical sensors positioned at different locations. Each sensor covers a specific field of view with appropriate magnification, and the system integrates data from all sensors to achieve both high local accuracy and comprehensive coverage of the entire component area.
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
Enhances energy density and reduces the risk of internal short circuits, allowing for smaller device dimensions and improved safety in medical applications.
Implementation Method 1
a first component is optically measured in order to determine an actual position of the first component
Implementation Method 2
the first component is gripped with a gripper... the actual position of the first component is adjusted if a deviation between the actual position and the desired position has been determined
Data Source
AI summary
The invention relates to methods for manufacturing an energy storage of an electrolytic capacitor, to a method for manufacturing a foil electrode of an aluminum electrolytic capacitor, to a device for manipulating a component of an aluminum electrolytic capacitor, to specifically designed foil electrodes for an aluminum electrolytic capacitor, to a method and a device for analyzing a quality of a section of paper to be used as separator of an electrolytic capacitor, and to a specifically designed electrolytic capacitor.