Rubber Seal Conical Guide for Aluminum Capacitor Lead Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing techniques for inserting lead terminals through terminal passage holes in aluminum electrolytic capacitors often apply excessive load, deteriorating the capacitor element's characteristics and failing to reliably seal the periphery of the lead terminal from outside air.
Innovation Solution
A conical guide surface is formed between the round bar mating hole and the lead wire passage hole, with a passage guide part on the lead wire that gradually reduces in diameter, and the inner surfaces are coated with low-friction resin to facilitate insertion without excessive load and ensure sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead terminal is forcibly inserted through the terminal passage hole to seal the welded section from outside air, then the sealing reliability is improved, but the capacitor element may be damaged due to excessive load
Solution Approach 1:
A guide surface is introduced as an intermediary structure between the terminal passage hole and the lead terminal. This guide surface gradually transitions from a smaller diameter at the hole to a larger diameter, mediating the insertion process and distributing the load to prevent damage to the capacitor element while achieving proper sealing of the welded section.
Solution Approach 2:
The diameter of the terminal passage hole is changed along the insertion path, creating a tapered guide surface. The hole diameter varies from smaller at the entry point to larger at the exit point, allowing the lead terminal to be inserted with controlled force that seals the welded section without damaging the capacitor element.
2Reliability
If the terminal passage hole diameter is reduced to seal the welded section, then the sealing effectiveness is improved, but the insertion force required increases and may damage the capacitor element
Solution Approach 1:
The terminal passage hole is segmented into different diameter sections along its length. The upper portion has a smaller diameter to provide sealing, while the lower portion has a larger diameter to facilitate insertion. This segmentation allows both sealing effectiveness and reduced insertion force to be achieved simultaneously.
Solution Approach 2:
The solution moves from a uniform diameter hole to a tapered hole, adding dimensional variation along the insertion path. This dimensional change allows the hole to provide both sealing (at the narrower upper section) and easy insertion (at the wider lower section)
Solution Approach 3:
The tapered guide surface acts as an intermediary that mediates between the small diameter needed for sealing and the large diameter needed for easy insertion. It provides a gradual transition that reduces insertion force while maintaining sealing effectiveness.
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 method allows for the insertion of lead terminals without damaging the capacitor element while effectively sealing the lead terminal from outside air, reducing whisker growth and improving manufacturing yield and productivity.
Implementation Method 1
the inner surfaces are coated with low-friction resin to facilitate insertion without excessive load
Data Source
Figure 1
Figure 2
Figure 3~4(c)
AI summary
A lead terminal is passed through a terminal passage hole of a rubber seal, without imposing an excessive burden such that the characteristics of the capacitor element would be degraded, and while maintaining a state of reliable isolation from the outside air. In an aluminum electrolytic capacitor in which the hole diameter f2 of a lead wire passage hole (52) is smaller than the outside diameter f1 of an outside lead wire (22), the outside lead wire (22) being forcibly passed to the outside through lead wire passage hole (52), a conical guide surface (53) of progressively smaller diameter is formed between a round bar mating hole (51) and the lead wire passage hole (52) within a terminal passage hole (5). A passage guide part (222) of progressively smaller diameter from a lead wire body (221) is integrally furnished at an end of the outside lead wire (22) so as to have a smaller diameter f3 than the hole diameter f2 of the lead wire passage hole (52), forming a conical sloped surface (223) having a predetermined angle on the peripheral surface of the passage guide part (222). Further, the terminal passage hole (5) is coated with low-friction resin like polyparaxylene or silicone oil emulsion.