Flat Anode Lead-Out Wire Structure for Stable Capacitor Welding
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Solution Overview
Problem
The cylindrical structure of anode lead-out wires in solid electrolytic capacitors can cause welding failures and bending issues during manufacturing, leading to reduced yield.
Innovation Solution
The anode lead-out wire is designed with a flat cross-section and recesses on its surface, featuring outward extending linear parts, which enhances stability and prevents bending during insertion into anode body powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the anode lead-out wire has a cylindrical structure, then the manufacturing process is simple, but welding failures occur and the wire may bend during insertion
Solution Approach 1:
The patent applies asymmetry by changing the anode lead-out wire from a symmetric cylindrical structure to an asymmetric flat structure with recesses on one or both surfaces. This asymmetric design provides flat contact surfaces for welding, improving welding reliability while preventing bending during insertion into the anode body powder.
Solution Approach 2:
The patent applies local quality by creating recesses only on specific surfaces of the anode lead-out wire rather than modifying the entire wire uniformly. The recesses are localized features that provide welding surfaces where needed, while maintaining the overall wire structure. This local modification improves welding reliability without requiring complete structural redesign.
2Volume of moving object
If the anode lead-out wire is thinned to reduce capacitor thickness, then the capacitor size is reduced, but the wire becomes more prone to bending
Solution Approach 1:
The flat asymmetric structure with recesses provides increased moment of inertia and structural rigidity compared to a thin cylindrical wire, enabling the wire to maintain bending resistance even when thinned to reduce capacitor thickness.
Solution Approach 2:
The recesses are formed in advance on the anode lead-out wire before insertion into the anode body powder. These pre-formed recesses provide structural reinforcement and flat contact surfaces that prevent bending during the insertion process, allowing the wire to be thinner without sacrificing strength.
3Stability of the object's composition
If the anode lead-out wire has a flat cross section without recesses, then the wire is less prone to bending, but welding failures still occur
Solution Approach 1:
The recesses are localized features created on specific surfaces of the flat anode lead-out wire. These local modifications provide the necessary welding surfaces and structural features for reliable welding, while the overall flat cross-section maintains the wire's shape stability and bending resistance.
Data Source
AI summary
A solid electrolytic capacitor capable of improving manufacturing yield is provided. A solid electrolytic capacitor according to one aspect of the present disclosure includes an anode lead-out wire and a capacitor element in which the anode lead-out wire is embedded. The cross section of at least a part of the anode lead-out wire in a direction in which the anode lead-out wire is extended has a flat shape, and a recess provided in a central part, a first linear part that is extended outward from one side of the recess, and a second linear part that is extended outward from another side of the recess are formed in at least one of an upper surface and a lower surface of the anode lead-out wire having the flat shape.