Electrolytic Capacitor Self-Alignment Separator Recesses
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Solution Overview
Problem
Stacked electrolytic capacitors face challenges due to alignment holes that reduce surface area, lead to gas-rich, electrolyte-starved regions, and increase the risk of device failure, making them larger and more complex, which complicates manufacturing and alignment.
Innovation Solution
The design incorporates a cathode with a conductive sheet featuring a central portion and two tails with recesses for alignment, along with a separator and anode with recesses, allowing for self-alignment without internal mechanical features, maintaining adequate separator coverage and preventing physical and electrical breakdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment holes are used in anodes and cathodes to ensure precision physical alignment during assembly, then manufacturing alignment is improved, but the surface area of each anode and cathode is reduced
Solution Approach 1:
The alignment function is extracted from the anode and cathode bodies and transferred to dedicated alignment features on the separator. The separator is modified to include protrusions that extend into recesses on the anode and cathode, creating self-aligning features without removing material from the electroactive surfaces of the electrodes.
Solution Approach 2:
The separator serves as an intermediary component that provides the alignment function. By placing alignment protrusions on the separator rather than on the electrodes themselves, the mediator (separator) enables precise alignment while preserving the full surface area of the electroactive electrode materials.
2Manufacturing precision
If alignment holes are used to ensure component alignment, then assembly alignment is improved, but the overall physical outline of components must be enlarged to compensate for lost surface area
Solution Approach 1:
The alignment function is extracted from the electrode structures and relocated to the separator component. This allows the electrodes to maintain their full surface area without requiring compensatory size increases, thereby reducing the overall capacitor volume while preserving alignment precision.
3Manufacturing precision
If alignment holes are used to ensure physical alignment, then assembly alignment is improved, but gas-rich, electrolyte-starved regions are created leading to latent failure
Solution Approach 1:
Instead of creating harmful gas-trapping cavities with holes, the invention uses solid protrusions on the separator that actively promote uniform electrolyte distribution. The protrusions guide electrolyte flow and prevent stagnation zones, converting a potential structural weakness into a feature that enhances reliability.
4Manufacturing precision
If alignment holes are used to ensure physical alignment, then assembly alignment is improved, but the device complexity and manufacturing challenge increase
Solution Approach 1:
The alignment function is merged with the separator component rather than being a separate feature on multiple components. By incorporating alignment protrusions directly into the separator structure, the invention reduces the number of separate alignment features needed and simplifies the overall manufacturing process.
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 configuration enables the manufacture of compact, high-energy-density capacitors with improved packaging efficiency, reduced risk of failure, and simplified manufacturing by eliminating the need for complex alignment features, while maintaining effective separation and alignment of components.
Implementation Method 1
a dielectric material disposed on a surface of the conductive anode
Implementation Method 2
an electrolyte disposed between the anode and the cathode
Data Source
AI summary
The electrolytic capacitor has a conductive sheet with a central portion defined by a peripheral edge, a first tail extending out from the peripheral edge in a first direction, and a second tail extending out from the peripheral edge in a second direction. The second direction is opposite the first direction. The first tail and the second tail each have a free end with a first recess at the free.