Electrolytic Capacitor Winding Core for Lead Terminal Positioning
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Solution Overview
Problem
The challenge in manufacturing electrolytic capacitors is the difficulty in accurately arranging multiple lead terminals due to process variations, which becomes more pronounced with an increasing number of terminals, leading to displacement issues that are hard to comply with standards.
Innovation Solution
A method involving the use of a winding core with a cross-sectional shape that matches the number of lead terminals, either polygonal or circular, to ensure that each lead terminal is positioned on a flat surface during the winding process, thereby maintaining their correct placement and suppressing displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more lead terminals are arranged on the foils to reduce ESL and ESR, then the capacitor performance is improved, but the difficulty of accurately arranging the lead terminals increases due to process variations
Solution Approach 1:
A winding core is introduced as an intermediary tool during the winding process. The core features a cross-sectional shape with flat surfaces that correspond to the number of lead terminals. These flat surfaces act as positioning references that guide the foils and lead terminals into correct positions during winding, thereby maintaining arrangement accuracy even when multiple terminals are present
Solution Approach 2:
The invention changes the geometric parameter of the winding core from a conventional circular cross-section to a custom cross-section with flat surfaces. This parameter change allows the core to provide positioning references for multiple lead terminals, enabling accurate arrangement of three or more terminals while maintaining manufacturing feasibility
2Ease of manufacture
If a conventional circular winding core is used, then the winding process is simple, but the lead terminals cannot be accurately positioned when three or more terminals are present
Solution Approach 1:
The cross-sectional shape parameter of the winding core is changed from circular to a shape with flat surfaces. This modification maintains the ease of manufacturing the core itself while providing geometric references that enable accurate positioning of multiple lead terminals during the winding process
3Productivity
If process variations occur during winding, then manufacturing flexibility is maintained, but lead terminal displacement increases making it difficult to comply with standards
Solution Approach 1:
The winding core with flat surfaces provides pre-established positioning references that cushion against process variations during winding. The geometric features of the core compensate for potential displacements by providing physical guides that maintain lead terminal positions within specified standards despite variations in the winding process
Data Source
AI summary
Electrode lead terminals in a number not less than three are attached to a cathode foil and an anode foil. The electrode lead terminals include at least one cathode lead terminal attached to the cathode foil and at least one anode lead terminal attached to the anode foil. A winding core having an axis is prepared. The cathode foil and the anode foil are wound around the winding core, being overlapped each other. A cross section of the winding core perpendicular to the axis includes an outer edge having a portion along each side of a polygon with the above number of sides. Thereby, a method for manufacturing an electrolytic capacitor capable of suppressing displacement of a lead terminal can be provided.