Fluted anode with minimal density gradients and capacitor comprising same

1. An anode comprising:

an anode body with a first side and a second side opposite to said first side;

first flutes on said first side and second flutes on said second side; and

wherein said first flutes and said second flutes are offset.

2. The anode of claim 1 wherein said first flutes each have a first flute wall and said second flutes each have a second flute wall wherein a cross-sectional area of said anode body between a planer projection of said first flute wall and a planer projection of said second flute wall is less than 50% of the total cross-sectional area of said anode body.

3. The anode of claim 2 wherein said cross-sectional area of said anode body between said planer projection of said first flute wall and said planer projection of said second flute wall is less than 30% of said total cross-sectional area of said anode body.

4. The anode of claim 3 wherein said cross-sectional area of said anode body between said planer projection of said first flute wall and said planer projection of said second flute wall is less than 20% of said total cross-sectional area of said anode body.

5. The anode of claim 1 wherein a parallel distance across said anode body deviates by less than 20% of the average of all parallel distances across said anode body.

6. The anode of claim 5 wherein said parallel distance across said anode body deviates by less than 5% of the average of all parallel distances across said anode body.

7. The anode of claim 1 wherein a depth of said first flute (TD) is related to a depth of said second flute (BD) by the equation:

TD≅BD *(1 −CR )

wherein CR is the compaction ratio percentage defined as the final compression height divided by the initial powder fill height.

8. The anode of claim 1 comprising at least one anode lead wire extending therefrom.

9. The anode of claim 8 comprising multiple anode lead wires extending therefrom.

10. The anode of claim 8 wherein said at least one anode wire has a cross-sectional aspect ratio of at least 2.0 to no more than 100.0.

11. A capacitor comprising the anode of claim 9 .

12. A capacitor comprising the anode of claim 10 .

13. A capacitor comprising the anode of claim 1 .

14. An anode comprising a radially compressed anode body with a first side and a second side opposite to said first side;

first flutes on said first side and second flutes on said second side; and

wherein said first flutes and said second flutes are offset.

15. The anode of claim 14 wherein said anode has a percent deviation in density in any region of said anode of no more than 20% from the average density.

16. The anode of claim 15 wherein said anode has a percent deviation in density in any region of said anode of no more than 10% from the average density.

17. The anode of claim 16 wherein said anode has a percent deviation in density in any region of said anode of no more than 5% from the average density.

18. An anode comprising an anode body with a first side and a second side opposite to said first side;

first flutes on said first side and second flutes on said second side; and

wherein said first flutes have a depth which is at least 50% more than a depth of said second flutes.

19. The anode of claim 18 wherein said first flutes have a depth which is at least 100% more than a depth of said second flutes.

20. The anode of claim 19 wherein said first flutes have a depth which is at least 200% more than a depth of said second flutes.

21. The anode of claim 18 further comprising an anode lead wire extending from said anode.

22. The anode of claim 21 further comprising more than one anode lead wire extending from said anode.

23. The anode of claim 21 comprising an anode wire with an aspect ratio of at least 2.0 to no more than 100.0.

24. A capacitor comprising the anode of claim 18 .

25. The capacitor of claim 24 further comprising a cathode lead frame.

26. The capacitor of claim 24 wherein said cathode lead frame is on said first side of said anode.

27. The capacitor of claim 24 wherein said cathode lead frame is on said second side of said anode.

28. A process for forming an anode comprising the steps of:

placing a powder between a first die and a second die wherein said first die has first flutes and said second die has second flutes and said first flutes and said second flutes are offset;

placing at least one anode wire in said powder; and

decreasing the distance between said first die and said second die perpendicular to said at least one anode wire and compressing said powder there between.

29. The process of claim 28 wherein a depth of said first flute (TD) is related to a depth of said second flute (BD) by the equation:

TD≅BD *(1 −CR )

wherein CR is the compaction ratio percentage defined as the final compression height divided by the initial powder fill height.

30. The process of claim 28 further comprising placing a second anode lead wire in said powder prior to said decreasing.

31. The process of claim 28 wherein said first flutes have a depth which is at least 50% more than a depth of said second flutes.

32. The process of claim 31 wherein said first flutes have a depth which is at least 100% more than a depth of said second flutes.

33. The process of claim 32 wherein said first flutes have a depth which is at least 200% more than a depth of said second flutes.

34. A process for forming an anode comprising the steps of:

placing a powder between a first die and a second die wherein said first die has first flutes and said second die has second flutes and said first flutes have a first depth and said second flutes have a second depth;

placing at least one anode wire in said powder wherein said anode wire has a cross-sectional aspect ratio of at least 2.0 to no more than 100.0; and

decreasing the distance between said first die and said second die perpendicular to said at least one anode wire and compressing said powder there between.

35. The process of claim 34 further comprising placing a second anode lead wire in said powder prior to said decreasing.

36. A process for forming an anode comprising the steps of:

placing a powder between a first die and a second die wherein said first die has first flutes and said second die has second flutes and said first flutes have a first depth and said second flutes have a second depth;

placing at least one anode wire in said powder; and

decreasing the distance between said first die and said second die perpendicular to said at least one anode wire and compressing said powder there between wherein a depth of said first flute (TD) is related to a depth of said second flute (BD) by the equation:

TD=BD *(1 −CR )

wherein CR is the compaction ratio percentage defined as the final compression height divided by the initial powder fill height.

37. A process for forming an anode comprising the steps of:

placing a powder between a first die and a second die wherein said first die has first flutes and said second die has second flutes and said first flutes have a first depth and said second flutes have a second depth;

placing at least one anode wire in said powder; and

decreasing the distance between said first die and said second die perpendicular to said at least one anode wire and compressing said powder there between wherein said first flutes have a depth which is at least 50% more than a depth of said second flutes.

38. The process of claim 37 wherein said first flutes have a depth which is at least 100% more than a depth of said second flutes.

39. The process of claim 38 wherein said first flutes have a depth which is at least 200% more than a depth of said second flutes.

40. An anode comprising an anode body with a first side and a second side opposite to said first side;

first flutes on said first side; and

an anode wire extending from said anode wherein said anode wire has a cross-sectional aspect ratio of at least 2.0 to no more than 100.0.

41. The anode of claim 40 further comprising at least two anode wires with said cross-sectional aspect ratio of at least 2.0 to no more than 100.0.

42. The anode of claim 40 further comprising second flutes on a second side.

43. A capacitor comprising the anode of claim 40 .

44. An anode comprising an anode body with a first side and a second side opposite to said first side;

first flutes on said first side; and

an anode wire extending from said anode wherein said anode wire has a cross-sectional aspect ratio of at least 2.0 to no more than 100.0 further comprising second flutes on a second side wherein said first flutes have a depth which is at least 50% more than a depth of said second flutes.

45. The anode of claim 44 wherein said first flutes have a depth which is at least 100% more than a depth of said second flutes.

46. The anode of claim 45 wherein said first flutes have a depth which is at least 200% more than a depth of said second flutes.

47. An anode comprising:

an anode body with a first side and a second side opposite to said first side;

first flutes on said first side; and

at least two anode lead wires extending from said anode body wherein at least one anode lead wire of said anode lead wires has an aspect ratio of at least 2.0 to no more than 100.0.

48. A capacitor comprising the anode of claim 47 .