Fluted anode with minimal density gradients and capacitor comprising same

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.

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.

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.

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.

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.