Electrolytic Capacitor Seal Geometry for Longer-Life Canister Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional capacitor manufacturing methods often result in inadequate seal integrity, leading to reduced operational lifespan due to insufficient contact area between the canister edge and lid, especially under varying environmental conditions such as temperature and vibration.
Innovation Solution
A method involving preforming the canister edge to increase its thickness and surface area, combined with an oblique angle and elastomer protuberance, to enhance the seal contact area and compressive force, thereby improving seal integrity and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the canister edge is preformed to increase thickness and surface area, then seal integrity is improved, but device complexity increases
Solution Approach 1:
The canister edge is preformed during the canister fabrication process to create an oblique angle and increased thickness before the sealing operation. This preliminary action ensures that when the lid is attached, the edge already has the necessary geometry to create an enhanced seal contact area with the elastomer, eliminating the need for additional post-forming operations and improving reliability while managing complexity.
Solution Approach 2:
The canister edge geometry is modified by changing key parameters: the thickness is increased and the angle is set to oblique (non-perpendicular) relative to the canister axis. These parameter changes create a larger contact area with the elastomer seal, improving seal integrity and reliability without requiring fundamentally new manufacturing processes.
2Reliability
If the canister edge is folded or rolled to increase thickness, then seal contact area is improved, but manufacturing precision requirements increase
Solution Approach 1:
Instead of folding or rolling the edge multiple times which would create complex geometry and high precision requirements, the invention changes the fundamental parameter of the edge geometry to a simple oblique angle with increased thickness. This parameter change achieves the goal of larger seal contact area while maintaining manageable manufacturing precision requirements through a single-forming operation rather than multiple folding/rolling steps.
3Duration of action of stationary object
If a thicker canister edge is used, then seal longevity is improved, but material usage increases
Solution Approach 1:
The canister is designed with non-uniform thickness: the edge portion has increased thickness to provide enhanced seal contact area and improved seal longevity, while the body of the canister maintains its standard, thinner wall construction. This local quality approach ensures that additional material is used only where it is needed for seal improvement, rather than increasing the material usage throughout the entire canister structure.
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 enhanced seal integrity increases the operational lifespan of capacitors by up to 460% under specific conditions, effectively addressing the limitations of traditional manufacturing methods.
Implementation Method 1
the lid, comprising an elastomer coating on one surface of the lid, wherein a contact area between the edge and the elastomer coating is greater than an area computed by a formula
Data Source
AI summary
Electrolytic capacitors may use a canister and a lid to confine an electrolyte and prevent the electrolyte from evaporating during use, and an improved seal between the canister and the lid may be achieved by increasing the surface area of the seal. For example, the surface area of the seal may be increased by changing the shape and/or thickness of the canister edge. For example, the surface area of the seal may be increased by changing the shape of an elastomer layer of the lid and/or adding an annular protuberance at the circumference of the lid. For example, the surface area of the seal may be changed by changing the process for forming the edge during the capacitor sealing.