Hybrid electrolytic capacitor device and method

Abstract

This disclosure relates to a hybrid electrolytic capacitor device and method. The hybrid capacitor includes a cathode foil, an anode foil, a negative electrode, and a positive electrode. The cathode foil and the negative electrode are connected by laser welding, and the anode foil and the positive electrode are connected by laser welding. This disclosure also provides a hybrid capacitor module, including multiple hybrid capacitors, a positive bus, a negative bus, and an external connector. The negative electrode of each hybrid capacitor is connected to the negative bus, and the positive electrode is connected to the positive bus. This disclosure also provides a method for manufacturing the hybrid capacitor module. This invention, through laser welding and a PCB-free structure, significantly reduces internal resistance, improves current collection capacity and heat dissipation performance, extends service life, improves space utilization, and reduces assembly costs, making it suitable for high-current, high-reliability applications.

Description

[0001] Cross-reference to related applications This application claims priority to U.S. Provisional Application No. 63 / 787,628, entitled “Hybrid Electrolytic Capacitor Apparatus and Method,” filed April 11, 2025, and U.S. Application No. 19 / 643,587, entitled “Hybrid Electrolytic Capacitor Apparatus and Method,” filed April 9, 2026, which is incorporated herein by reference. Technical Field

[0002] This invention generally relates to the field of electrolytic capacitors, and specific embodiments relate to a hybrid electrolytic capacitor device and method. Background Technology

[0003] Traditional electrolytic capacitors use a "horn-shaped" lead configuration, with the capacitor leads passing downwards through a printed circuit board (PCB) for electrical connection. Series and parallel connections between capacitors are achieved through PCB wiring. For example... Figure 1 As shown, multiple electrolytic capacitors are mounted vertically on the PCB, with their leads extending through the PCB board. This structure results in long current paths and a high dependence on the PCB layout for current distribution and convergence. The PCB size and the through-board capacitor leads reduce space utilization and limit design compactness.

[0004] Furthermore, the copper foil in a PCB, which serves as the main conductive path between components, has a limited thickness, insufficient current-carrying capacity, and is prone to thermal stress, reducing capacitor reliability and accelerating aging. For example... Figure 2 As shown, traditional electrolytic capacitors employ a cold-riveting structure, connecting internal electrodes to external terminals via conductive strips. This structure has a small conductive cross-sectional area, a long current path, and poor current collection efficiency, further exacerbating heat generation and performance degradation.

[0005] Therefore, there is an urgent need to develop technologies and structures that can comprehensively improve the performance of electrolytic capacitors. Summary of the Invention

[0006] This disclosure provides a hybrid electrolytic capacitor device and method, achieving corresponding technical advantages.

[0007] According to one aspect of this disclosure, a hybrid capacitor is provided, comprising a cathode foil, an anode foil, a negative electrode, and a positive electrode, wherein the cathode foil and the negative electrode are connected by laser welding, and the anode foil and the positive electrode are connected by laser welding.

[0008] According to one aspect of this disclosure, a hybrid capacitor module is provided, including a plurality of hybrid capacitors, a positive bus, a negative bus, and a connector for interfacing with an external circuit. Each hybrid capacitor includes a negative terminal and a positive terminal, the negative terminal being connected to the negative bus and the positive terminal being connected to the positive bus.

[0009] According to another aspect of this disclosure, a method for manufacturing a hybrid electrolytic capacitor is provided, comprising: providing a plurality of hybrid capacitors each having a positive electrode and a negative electrode; arranging the plurality of hybrid capacitors side by side in parallel; connecting the negative electrodes of the plurality of hybrid capacitors to a negative busbar by laser welding; connecting the positive electrodes of the plurality of hybrid capacitors to a positive busbar by laser welding; encapsulating the plurality of hybrid capacitors and the busbar in a housing; and providing a connector for interfacing with an external circuit and fixing the hybrid capacitor module in the housing.

[0010] Features in one embodiment can be used in combination with those in other embodiments, and optional features of the above apparatus can be used in combination with the method.

[0011] The foregoing provides a general overview of the features and technical advantages of this disclosure to facilitate a better understanding of the detailed description that follows. Additional features and advantages of this disclosure are described below and form the subject matter of the claims. Those skilled in the art will understand that the concepts and specific embodiments disclosed herein can be readily used as a basis for modifying or designing other structures or processes to achieve the same purpose of this disclosure. Those skilled in the art will also understand that such equivalent structures do not depart from the spirit and scope of this disclosure as defined by the appended claims. Attached Figure Description

[0012] By reading the following detailed description of exemplary embodiments, those skilled in the art will understand the advantages and benefits of the present invention, as well as other advantages and benefits. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. Wherein: Figure 1 A three-dimensional schematic diagram of a traditional electrolytic capacitor mounted on a printed circuit board; Figure 2 for Figure 1 The diagram shows an exploded view of a traditional electrolytic capacitor. Figure 3 This is an exploded view of an example hybrid electrolytic capacitor described in various embodiments of this disclosure; Figure 4 This is an exploded view of an example hybrid electrolytic capacitor described in various embodiments of this disclosure; Figure 5 This is an exploded view of an example hybrid electrolytic capacitor described in various embodiments of this disclosure; Figure 6 This is an exploded view of an example hybrid capacitor module described in various embodiments of this disclosure; Figure 7 This is a schematic diagram of an example hybrid capacitor bank described in various embodiments of this disclosure; Figure 8 This is a schematic diagram of an example hybrid capacitor bank described in various embodiments of this disclosure; Figure 9 This is a schematic diagram of an example hybrid capacitor module and hybrid capacitor bank described in various embodiments of this disclosure; Figure 10 This is a flowchart illustrating an example method for preparing a hybrid capacitor module according to various embodiments of this disclosure.

[0013] Unless otherwise stated, corresponding numbers and symbols in different figures generally refer to corresponding parts. These figures are drawn to clearly illustrate relevant aspects of various embodiments and are not necessarily drawn to scale. Detailed Implementation

[0014] The preparation and use of embodiments of this disclosure are described in detail below. It should be understood that the concepts disclosed herein can be implemented in various specific scenarios, and the specific embodiments discussed herein are merely illustrative and do not limit the scope of the claims. Furthermore, various modifications, substitutions, and alterations can be made to this document without departing from the spirit and scope of this disclosure as defined by the appended claims.

[0015] Furthermore, one or more features of the following embodiments may be combined to form alternative embodiments not explicitly described, and all applicable features of such combinations are within the scope of this disclosure. Therefore, the appended claims are intended to cover such modifications or embodiments.

[0016] This disclosure will describe a hybrid electrolytic capacitor apparatus and method in a specific scenario, in conjunction with preferred embodiments. Various embodiments are described in detail below with reference to the accompanying drawings. In this disclosure, "hybrid electrolytic capacitor" and "hybrid capacitor" are used interchangeably.

[0017] Figure 3 and Figure 4 Examples of hybrid electrolytic capacitors according to various embodiments of this disclosure are shown. The hybrid electrolytic capacitor includes a cylindrical housing, a cathode foil, an anode foil, a positive electrode, a negative electrode, a top cover, and a base plate. The positive electrode is located at one end of the hybrid electrolytic capacitor and is supported by the base plate; in some embodiments, the positive electrode may be integrated onto or through the base plate. The negative electrode is located at the other end of the hybrid electrolytic capacitor; in some embodiments, the negative electrode may be integrated onto or through the top cover. The anode foil is connected to the positive electrode by laser welding, and the cathode foil is connected to the negative electrode by laser welding.

[0018] like Figure 4 As shown, the hybrid capacitor may further include a negative electrode and a positive electrode. In some embodiments, the negative electrode is an integral extension of the cathode foil, and the positive electrode is an integral extension of the anode foil. The positive electrode is soldered to the positive electrode, and the negative electrode is soldered to the negative electrode.

[0019] In some embodiments, the hybrid capacitor uses an all-aluminum cap instead of a rubber cap, which significantly improves structural strength and reduces electrolyte leakage rate by more than 10 times.

[0020] In some embodiments, the hybrid capacitor uses aluminum terminals welded to both ends, requiring only aluminum strips to be welded during assembly, whereas traditional capacitors require PCB soldering. Compared to traditional module assembly, the hybrid capacitor improves space utilization by 10% and reduces module assembly costs by 15%.

[0021] In terms of product performance, the internal resistance of the hybrid capacitor is 10% of that of the traditional capacitor, the ripple current capability is 10 times that of the traditional capacitor, and the service life is more than twice that of the traditional capacitor.

[0022] In terms of structure, the current-collecting capacity of the hybrid capacitor is 20 times that of the traditional capacitor. Taking the existing product (450V 100μF) as an example, the distance from the electrode to the current-collecting solder joint of the hybrid capacitor is less than 50mm, while the distance from the electrode to the current-collecting solder joint of the traditional capacitor is 1000mm; the current-collecting solder joint area of ​​the hybrid capacitor is 76 square millimeters, while the current-collecting solder joint area of ​​the traditional capacitor is 5 square millimeters.

[0023] The hybrid capacitor may also include an explosion-proof valve. In some embodiments, the explosion-proof valve is integrated into the top cover of the hybrid capacitor; in other embodiments, the explosion-proof valve is disposed on the side of the hybrid capacitor, such as... Figure 5 As shown.

[0024] Hybrid capacitors are assembled by directly welding aluminum strips to the positive and negative terminals, eliminating the need for PCBs and pin dimensions. At the same time, the thicker aluminum strips ensure higher current carrying capacity and mechanical strength.

[0025] like Figure 6 As shown, the hybrid capacitor module includes multiple hybrid capacitors, a negative bus, and a positive bus. In some embodiments, both the positive and negative buses are made of aluminum. The multiple hybrid capacitors are arranged side-by-side in parallel. The negative terminals of the hybrid capacitors are connected to the negative bus via laser welding, and the positive terminals are connected to the positive bus via laser welding. Figure 6 As shown, the explosion-proof valves of the hybrid capacitors are located on their respective sides; in an alternative embodiment, the explosion-proof valves may be located on the top cover of each hybrid capacitor, such as... Figure 3 As shown.

[0026] In some embodiments, such as Figure 7 As shown, the hybrid capacitor bank includes a casing, such as... Figure 6 The diagram shows a hybrid capacitor module and connector. The hybrid capacitor module is encapsulated within a housing, which provides mechanical protection and electrical insulation. The connector includes a positive terminal and a negative terminal. The positive terminal of the connector is electrically connected to the positive bus of the hybrid capacitor module, and the negative terminal is electrically connected to the negative bus of the hybrid capacitor module. The connector is used for interfacing with external circuitry and for securing the hybrid capacitor module within the housing, forming an integrated, compact capacitor bank assembly. Figure 7As shown, the width of the connector can be equal to or substantially equal to the width of the housing.

[0027] In some embodiments, such as Figure 8 As shown, the hybrid capacitor bank includes a housing, multiple hybrid capacitor modules, and connectors. The multiple hybrid capacitor modules are arranged side-by-side within the housing. The connector includes a positive terminal and a negative terminal; the positive terminal of the connector is electrically connected to the positive busbar of the multiple hybrid capacitor modules, and the negative terminal of the connector is electrically connected to the negative busbar of the multiple hybrid capacitor modules. The connector is used to secure the multiple hybrid capacitor modules within the housing and to achieve electrical connection with external systems. Figure 8 As shown, the width of the connector can be equal to or substantially equal to the width of the housing. Depending on the system voltage and energy storage requirements, the hybrid capacitor modules can be configured in parallel, series, or a combination of series and parallel connections.

[0028] In addition, liquid cooling can be used to enhance heat dissipation. For example... Figure 9 As shown, the liquid cooling channel can be integrated into or mounted on the housing of a hybrid capacitor module or hybrid capacitor bank. The liquid cooling connection includes an inlet, an outlet, and a liquid cooling connector. Depending on heat dissipation and structural requirements, the liquid cooling channel can adopt suitable configurations such as U-shaped or loop-shaped. Coolant enters the liquid cooling channel through the inlet, circulates, and flows out through the outlet, carrying away heat from the capacitor assembly. The liquid cooling connector is used for interfacing with external systems.

[0029] Figure 10 This is a flowchart illustrating an example method for preparing a hybrid capacitor module according to various embodiments of this disclosure.

[0030] Step 1002: Provide a plurality of hybrid capacitors, each hybrid capacitor including a positive terminal and a negative terminal; Step 1004: Arrange multiple hybrid capacitors side by side in parallel; Step 1006: Connect the negative terminals of multiple hybrid capacitors to the negative busbar by laser welding; Step 1008: Connect the positive terminals of multiple hybrid capacitors to the positive busbar by laser welding; Step 1010: Encapsulate multiple hybrid capacitors and busbars within a housing; Step 1012: Set up a connector for interfacing with external circuitry and securing the hybrid capacitor module inside the housing.

[0031] Although this disclosure has been described in detail above, it should be understood that various modifications, substitutions, and alterations can be made without departing from the spirit and scope of this disclosure as defined by the appended claims. Furthermore, the scope of this disclosure is not intended to be limited to the specific embodiments described herein. Those skilled in the art will readily understand from this disclosure that currently existing or subsequently developed processes, machines, articles, material compositions, apparatuses, methods, or steps can achieve substantially the same function or effect as the embodiments described herein. Therefore, the appended claims are intended to bring such processes, machines, articles, material compositions, apparatuses, methods, or steps within their scope of protection.

Claims

1. A hybrid capacitor, characterized in that, include: A cathode foil; an anode foil; a negative electrode; and a positive electrode; wherein the cathode foil and the negative electrode are connected by laser welding, and the anode foil and the positive electrode are connected by laser welding.

2. The hybrid capacitor according to claim 1, characterized in that, It also includes an explosion-proof valve, which is disposed on the side of the hybrid capacitor.

3. The hybrid capacitor according to claim 1, characterized in that, It also includes an explosion-proof valve, which is integrated into the top cover of the hybrid capacitor.

4. The hybrid capacitor according to claim 1, characterized in that, It also includes a cap disposed at one end of the hybrid capacitor, the cap being made of aluminum.

5. The hybrid capacitor according to claim 1, characterized in that, The cathode foil has an extension and is welded to the negative electrode, and the anode foil has an extension and is welded to the positive electrode.

6. A hybrid capacitor module, characterized in that, include: Multiple hybrid capacitors, each of which includes a negative terminal and a positive terminal; a positive bus; and a negative bus; And a connector for interfacing with an external circuit; wherein the negative terminals of the plurality of hybrid capacitors are connected to the negative bus, and the positive terminals of the plurality of hybrid capacitors are connected to the positive bus.

7. The hybrid capacitor module according to claim 6, characterized in that, The negative terminals of the plurality of hybrid capacitors are connected to the negative busbar by laser welding, and the positive terminals of the plurality of hybrid capacitors are connected to the positive busbar by laser welding.

8. The hybrid capacitor module according to claim 6, characterized in that, It also includes a housing, in which the plurality of hybrid capacitors are arranged side by side in parallel and encapsulated.

9. The hybrid capacitor module according to claim 6, characterized in that, The positive bus and the negative bus are made of aluminum.

10. The hybrid capacitor module according to claim 6, characterized in that, The multiple hybrid capacitors are arranged side by side in parallel to form an independent module.

11. The hybrid capacitor module according to claim 6, characterized in that, The negative busbar is electrically connected to the housing of the plurality of hybrid capacitors.

12. The hybrid capacitor module according to claim 6, characterized in that, It also includes liquid cooling channels.

13. The hybrid capacitor module according to claim 12, characterized in that, The liquid cooling channel is located on the outer casing and is used to circulate coolant for heat dissipation.

14. The hybrid capacitor module according to claim 12, characterized in that, The liquid cooling channel is connected to the negative busbar to achieve heat dissipation.

15. The hybrid capacitor module according to claim 6, characterized in that, Each of the hybrid capacitors also includes an explosion-proof valve disposed on its side.

16. The hybrid capacitor module according to claim 12, characterized in that, The liquid cooling channel is made of copper, aluminum, or their alloys.

17. A method, characterized in that, include: A plurality of hybrid capacitors are provided, each of the hybrid capacitors including a positive terminal and a negative terminal; the plurality of hybrid capacitors are arranged side by side in parallel. The negative terminal is connected to the negative busbar and the positive terminal is connected to the positive busbar by laser welding; the plurality of hybrid capacitors are then encapsulated in a housing. It also includes a connector for interfacing with external circuitry and securing the hybrid capacitor module within the housing.

18. The method according to claim 17, characterized in that, The negative bus and the positive bus are made of copper, aluminum or their alloys.

19. The method according to claim 17, characterized in that, Also includes: A liquid cooling channel is installed on the housing, and coolant is circulated in the liquid cooling channel to dissipate the heat generated by the plurality of hybrid capacitors.

20. The method according to claim 17, characterized in that, Each of the hybrid capacitors further includes a cathode foil and an anode foil, wherein the cathode foil is connected to the negative electrode by laser welding, and the anode foil is connected to the positive electrode by laser welding.

Images