Hybrid Electrolytic Capacitor Anode Processing for High-Voltage Dielectrics
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Solution Overview
Problem
Existing methods for manufacturing electrolytic capacitors are not suitable for hybrid electrolytic capacitors requiring high rated voltages, as they often involve dielectric layer formation methods used for general aluminum or solid electrolytic capacitors, leading to inefficiencies and challenges in using high-concentration chemical conversion liquids.
Innovation Solution
A manufacturing method for hybrid electrolytic capacitors involving the preparation of an anode substrate with first dielectric layers, connection of anode lead members, and formation of a second dielectric layer through chemical conversion treatment before forming the laminate, allowing for efficient use of high-concentration chemical conversion liquids and reducing discharge issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional anodizing methods are used to form dielectric layers, then the manufacturing process is simple, but the method is not suitable for hybrid electrolytic capacitors requiring high rated voltages
Solution Approach 1:
The dielectric layer formation process is divided into two distinct stages: first, forming an initial dielectric layer on the metal foil surface; second, forming a thicker dielectric layer on the end surface after winding. This segmentation allows each stage to be optimized for its specific purpose, enabling high voltage capability while maintaining process feasibility
Solution Approach 2:
The initial dielectric layer is formed on the metal foil before winding, preparing the surface for subsequent dielectric layer formation. This preliminary action ensures that the end surface has adequate dielectric coverage when the thicker layer is formed later, enabling high voltage operation
2Productivity
If high-concentration chemical conversion liquid is used, then dielectric layer formation efficiency is improved, but discharge occurs between anode and cathode
Solution Approach 1:
The anode substrate undergoes preliminary treatment by forming an initial dielectric layer and connecting lead members before immersion in the chemical conversion liquid. This preparation ensures that the anode is properly positioned and protected, allowing efficient dielectric layer formation without discharge issues
Solution Approach 2:
The patent introduces a chemical conversion liquid immersion process as an intermediary step between anode preparation and final assembly. This intermediary process allows controlled dielectric layer formation using high-concentration chemical conversion liquid while the anode lead members serve as intermediaries to manage electrical connections and prevent discharge
3Ease of manufacture
If dielectric layer is formed after winding, then manufacturing is simplified, but uniform dielectric layer formation is difficult and discharge risks increase
Solution Approach 1:
The manufacturing process is segmented into distinct phases: pre-winding anode preparation with initial dielectric layer formation, winding assembly, and post-winding end surface dielectric layer formation. This segmentation achieves both manufacturing simplicity and dielectric layer uniformity by treating different surfaces at optimal times
Solution Approach 2:
The anode substrate is preliminarily prepared with lead members and initial dielectric layer before winding, ensuring proper positioning and electrical connections. This preliminary preparation enables subsequent uniform dielectric layer formation on the end surface without compromising manufacturing efficiency
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
Enables the production of hybrid electrolytic capacitors with high rated voltages by ensuring uniform dielectric layer formation and minimizing discharge risks, while facilitating the use of high-concentration chemical conversion liquids.
Implementation Method 1
forming a second dielectric layer on the end surface by immersing the anode substrate in a chemical conversion liquid and subjecting the anode substrate to chemical conversion treatment
Data Source
AI summary
The disclosed manufacturing method includes: a step (i) of preparing an anode substrate having a metal foil exposed at an end surface of the anode substrate; a step (ii) of connecting a plurality of anode lead members to the anode substrate and forming a second dielectric layer on the end surface; a step (iii) of forming a plurality of the anode bodies to which the anode lead members are connected by cutting the anode substrate at a predetermined length; a step (iv) of forming a laminate by laminating the anode body, a cathode body, and a separator; and a step (v) of impregnating the laminate with a conductive polymer and an electrolytic solution. Step (ii) includes: connecting the plurality of anode lead members to the anode substrate; and forming the second dielectric layer on the end surface by immersing the anode substrate in a chemical conversion liquid.