Cathode Subassembly with Recessed Edge Alignment for Capacitors
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Solution Overview
Problem
Stacked electrolytic capacitors face challenges with alignment issues due to physical features like holes in separators and components, leading to reduced energy density, larger size, and potential for device failure from gas-rich, electrolyte-starved regions and misalignment during manufacturing.
Innovation Solution
A cathode subassembly design featuring a conductive foil sandwiched between two separator sheets with recessed portions, ensuring precise alignment and sealing to prevent electrical contact and discharge, while maintaining a compact footprint and efficient manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical alignment features like holes are added to separators and components, then manufacturing alignment precision is improved, but device complexity and lost surface area increase
Solution Approach 1:
The patent removes the alignment holes from the separator and component surfaces, extracting the problematic alignment feature entirely. Instead, it uses the natural peripheral edges of rectangular components to achieve alignment, eliminating the need for holes while maintaining manufacturing precision.
Solution Approach 2:
The patent applies different alignment strategies to different parts of the component. Rather than using holes throughout, it relies on the peripheral edges of rectangular components for alignment, utilizing the local geometric properties of the component boundaries to achieve precise stacking without adding complexity.
2Manufacturing precision
If alignment holes are created in separators and components, then assembly alignment is improved, but energy density decreases due to lost surface area
Solution Approach 1:
The patent extracts and removes the alignment holes from the design, eliminating the lost surface area that reduces energy density. By using peripheral edge alignment instead, the entire surface area of the separator and components is available for energy storage functions.
Solution Approach 2:
The patent merges the alignment function with the peripheral edges of the rectangular components themselves. The edges that define the component boundaries serve dual purposes: both as structural boundaries and as alignment features, eliminating the need for separate alignment holes.
3Manufacturing precision
If alignment holes and features are added to components, then stacking alignment is improved, but the overall device size increases
Solution Approach 1:
The patent removes alignment holes and protruding features that would increase the overall device footprint. By using the peripheral edges of rectangular components for alignment, the device maintains a compact rectangular shape without additional alignment structures.
Solution Approach 2:
The patent utilizes the local peripheral edges of rectangular components as alignment features, rather than adding global alignment structures. This approach maintains the compact overall device size while providing sufficient alignment precision through the natural boundaries of the components.
4Manufacturing precision
If complex alignment features are used, then manufacturing alignment is improved, but ease of manufacture decreases
Solution Approach 1:
The patent removes complex alignment features like holes and protrusions that complicate manufacturing. By using simple peripheral edge alignment of rectangular components, the manufacturing process becomes simpler and more straightforward.
Solution Approach 2:
Instead of adding alignment features to components, the patent inverts the approach and uses the absence of features (the peripheral edges themselves) for alignment. This inversion simplifies the manufacturing process by eliminating additional fabrication steps for alignment features.
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 solution enhances energy density, reduces the risk of device failure, and simplifies manufacturing by eliminating the need for complex alignment features, resulting in a more reliable and efficient stacked electrolytic capacitor configuration.
Implementation Method 1
the first and second separator sheets are adhered to each other in a sealing region
Data Source
AI summary
A cathode subassembly for use in an electrolytic capacitor may include a first separator sheet including a surface having first and second regions, where the second region extends from a perimeter of the first region to a first peripheral edge of the first sheet, a second peripheral edge of a second sheet is substantially aligned with the first peripheral edge, a conductive foil is sandwiched between the first and second sheets and disposed within the first region, the first and second sheets are adhered to each other in a sealing region extending from the second region to a region of a surface of the second sheet facing the second region, and the first sheet includes at least one first recess portion at the first peripheral edge aligned with at least one second recess portion at the second peripheral edge of the second sheet.