Oxide-Coated Capacitor Lead Wire for Moisture-Stable Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solid electrolytic capacitors face challenges with insulating rings that are expensive and ineffective in high moisture and temperature environments.
Innovation Solution
A solid electrolytic capacitor design featuring a lead wire with a core that extends outwardly from the capacitor element, coated with an oxide layer, and a method for forming this oxide layer through anodic oxidation after removing conductive material from the lead wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating rings are used to protect the lead wire, then the lead wire is protected from moisture, but the cost increases and effectiveness is reduced in high moisture and temperature environments
Solution Approach 1:
The patent removes the insulating ring component entirely and replaces it with an oxide layer formed directly on the lead wire surface through anodic oxidation. This extraction of the separate insulating component simplifies the overall structure while maintaining protection functionality through the integrated oxide coating.
Solution Approach 2:
The oxide layer acts as an intermediary substance that provides both electrical insulation and moisture protection simultaneously. This intermediary layer eliminates the need for separate insulating rings while addressing the limitations of existing protection methods in high humidity and temperature conditions.
2Reliability
If conductive polymer is removed from the lead wire, then leakage current is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary removal of conductive polymer from the lead wire surface before final assembly, and applies an oxide layer in advance to prevent future leakage issues. This preliminary action ensures low leakage current while the integrated process design minimizes manufacturing complexity.
Solution Approach 2:
The anodic oxidation process creates a self-forming protective oxide layer on the lead wire that automatically provides electrical insulation and moisture protection. This self-service mechanism eliminates the need for additional insulating components and simplifies the manufacturing process despite the extra oxidation step.
3Reliability
If an oxide layer is formed on the lead wire through anodic oxidation, then electrical properties are improved, but additional manufacturing steps are required
Solution Approach 1:
The patent combines multiple functions into the single oxide layer formation step: electrical insulation, moisture protection, and corrosion resistance are all achieved simultaneously through the anodic oxidation process. This merging of functions improves electrical properties while minimizing the impact on manufacturing efficiency by consolidating protection requirements into one process step.
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 capacitor exhibits improved electrical properties, including reduced leakage current and equivalent series resistance, and maintains performance in high humidity and temperature conditions.
Implementation Method 1
a method for forming this oxide layer through anodic oxidation after removing conductive material from the lead wire
Data Source
Figure 1
Figure 2a~3b
Figure 4a~4b
AI summary
A solid electrolytic capacitor that comprises a capacitor element, a lead wire, an anode termination, and a cathode termination is provided. The capacitor element contains a sintered porous anode body, a dielectric that overlies the anode body, and a solid electrolyte that overlies the dielectric. Further, the lead wire is in electrical contact with the anode body and contains a first region that is located in proximity to a surface of the capacitor element. The lead wire contains a core that extends outwardly from the surface, and an oxide layer coats at least a portion of the core within the first region.