A high-capacitance horn-shaped aluminum electrolytic capacitor with anode foil

Abstract

This utility model discloses a high-specific-capacitance horn-shaped aluminum electrolytic capacitor with anode foil, belonging to the technical field of electronic components. This high-specific-capacitance horn-shaped aluminum electrolytic capacitor with anode foil features an AlN ceramic coating on the inner side of the base to prevent moisture penetration from the bottom. Combined with the sealing boss on the top cover and the fluororubber sealing ring on the body, a double seal is formed, achieving a waterproof and dustproof rating of IP67. In humid environments, the capacitance decay rate is <3% after 1000 hours. Simultaneously, the porous structure formed by laser etching of the high-specific-capacitance anode foil increases the specific surface area by 50-100 times compared to traditional anode foil. Through optimized mechanical structure and safety design, the capacitor's vibration resistance reliability and operational safety are significantly enhanced, overcoming the shortcomings of traditional equipment where the tabs are prone to breakage under vibration and the explosion-proof threshold is unstable. The cathode foil tabs are fixed in both directions by the tab connecting seat on the base and the buffer sleeve on the top cover. Combined with the silicone buffer pad between the top cover and the horn-shaped terminals, it can absorb stress under random vibration.

Description

Technical Field

[0001] This utility model relates to the field of electronic components technology, and in particular to a high-capacitance horn-shaped aluminum electrolytic capacitor with anode foil. Background Technology

[0002] In the field of electronic components, aluminum electrolytic capacitors have long been used as key energy storage components for terminal equipment such as consumer electronics, industrial control, and new energy vehicles due to their core advantages of controllable cost and wide capacity coverage. For example, they play a role in filtering and voltage stabilization in switching power supplies and realize the temporary storage and release of electrical energy in vehicle DC-DC converters. Their performance directly determines the operational stability and service life of terminal equipment. As downstream industries accelerate their transformation towards miniaturization, high power, and adaptation to complex scenarios, the technical limitations of traditional anode foil horn aluminum electrolytic capacitors are becoming increasingly prominent, making it difficult to meet the stringent requirements of the new generation of equipment.

[0003] High specific capacity performance faces bottlenecks and cannot adapt to the trend of device miniaturization. Currently, products such as micro-inverters and portable energy storage power supplies have an increasingly urgent need for small size and high capacity. This goal highly depends on the optimization of the specific surface area of ​​the anode foil. However, traditional anode foils generally adopt chemical etching processes, which form a porous structure through acid and alkali solution corrosion. Due to the randomness of the process, the etched pore size is uneven and the distribution is disordered. The specific surface area can only be increased by 30-50 times compared with the original aluminum foil. The capacity per unit volume is generally low, making it difficult to break through the upper limit of capacity density. Traditional electrode groups are simply wound together by anode foil, cathode foil and isolation paper. They lack the synergistic optimization of conductive medium. The current conduction path is long and the equivalent series resistance is high, which further limits the capacity output. In addition, the porous structure of traditional anode foil is prone to capacity decay due to uneven electrolyte wetting. In high-temperature environments above 85°C, the capacity decay rate can reach more than 20% after 1000 hours, which cannot meet the long-term use requirements of high reliability scenarios.

[0004] Outdoor applications of consumer electronics and industrial control cabinets often face high humidity and corrosive gas environments. However, the protection design of traditional aluminum electrolytic capacitors has obvious defects: the sealing structure mostly uses a single epoxy resin bond. Epoxy resin is prone to moisture absorption and aging in humid environments, and the sealing performance deteriorates rapidly with the use time. After water vapor seeps in, it reacts with the electrolyte to generate impurities, resulting in a sharp increase in leakage current. In extreme cases, it may even cause an internal short circuit.

[0005] Insufficient mechanical reliability and poor vibration resistance make it difficult to meet the requirements of harsh scenarios. Scenarios such as automotive electronics and engineering machinery have stringent requirements for the vibration resistance of capacitors, but the mechanical structure design of traditional horn-shaped aluminum electrolytic capacitors has significant shortcomings: the electrode fixing method is simple, relying only on the top to the terminal welding, and there is no support structure at the bottom. During vibration, the electrode is prone to cracking at the welding point due to stress concentration.

[0006] Some products add plastic supports at the bottom of the tabs, but the support base has poor insulation performance, which can easily lead to short circuit risks. However, existing improvements are mostly aimed at single pain points and lack systematic optimization of high specific capacitance, environmental adaptability, mechanical reliability and safety. They cannot meet the downstream industry's demand for comprehensive capacitor performance. Therefore, there is an urgent need for a new type of anode foil high specific capacitance horn aluminum electrolytic capacitor that can comprehensively solve the above-mentioned technical bottlenecks. Utility Model Content

[0007] The purpose of this invention is to at least solve one of the technical problems existing in the prior art, and to provide a high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil, which can solve the above problems.

[0008] To achieve the above objectives, this utility model provides the following technical solution: a high specific capacitance horn aluminum electrolytic capacitor with anode foil, comprising a body, a base fixedly connected to the lower end of the body, a positioning protrusion fixedly connected to the lower end of the base, a top cover fixedly connected to the upper end of the body, a sealing ring fixedly connected to the inner side of the upper end of the body, and a sealing boss fixedly connected to the lower end of the top cover corresponding to the position of the sealing ring, wherein the sealing boss and the sealing ring are in a sealing fit.

[0009] The device body is provided with a separator paper, a cathode aluminum foil, and a high specific capacitance anode foil. The separator paper, cathode aluminum foil, and high specific capacitance anode foil are wound to form a conductive polymer composite electrode group. The separator paper is located on the inside, the cathode aluminum foil is wrapped on the outside of the separator paper, and the high specific capacitance anode foil is wrapped on the outside of the cathode aluminum foil. The high specific capacitance anode foil and the inner wall of the device body are filled with electrolyte.

[0010] An electrode tab connecting seat is fixedly connected to the inner side of the base, and a cathode foil electrode tab is fixedly connected to the electrode tab connecting seat. The other end of the cathode foil electrode tab is connected to the cathode aluminum foil. An anode foil electrode tab is provided on the side of the device body opposite to the cathode foil electrode tab. One end of the anode foil electrode tab is connected to the high specific capacity anode foil.

[0011] The upper inner wall of the device is circumferentially fixed with an explosion-proof weak zone, and the inner surface of the base is covered with a ceramic coating.

[0012] Two through holes are provided in the middle of the top cover. A buffer sleeve is fixedly connected in the through holes. The ends of the cathode foil tabs and anode foil tabs away from the electrode group pass through the buffer sleeves in the corresponding through holes. A buffer pad is fixedly connected to the upper end of the top cover at the position corresponding to the through holes. A tab connecting seat is fixedly connected to the buffer pad. A horn terminal is fixedly connected to the tab connecting seat. The ends of the cathode foil tabs and anode foil tabs that pass through the through holes are fixedly connected to the corresponding tab connecting seats.

[0013] Preferably, four positioning protrusions are provided and are evenly distributed along the lower end face of the base.

[0014] Preferably, the sealing ring is made of fluororubber and has a U-shaped cross-section. The cross-sectional shape of the sealing boss is adapted to the U-shaped opening of the sealing ring, and the sealing boss and the sealing ring are interference fit.

[0015] Preferably, the surface of the high specific capacity anode foil is laser-etched to form a porous structure, and its surface is covered with a conductive polymer coating.

[0016] Preferably, the electrode connector includes a ceramic insulating substrate and a copper conductive sheet embedded in the substrate, and the cathode foil electrode, anode foil electrode, and copper conductive sheet are fixed by laser welding.

[0017] Preferably, the thickness of the explosion-proof weak zone is 40% of the wall thickness of the device, and its surface is provided with an annular groove.

[0018] Preferably, the buffer sleeve is made of silicone material, with anti-slip texture on its inner wall, and is interference-fitted with the cathode foil tab and the anode foil tab.

[0019] Preferably, the bullhorn terminal is integrally die-cast from aluminum alloy, with an arc-shaped reinforcing rib at its root, and the buffer pad is interference-fitted with the electrode tab.

[0020] Compared with the prior art, the beneficial effects of this utility model are:

[0021] 1. This high-capacitance horn-shaped aluminum electrolytic capacitor with anode foil features an AlN ceramic coating on the inner side of the base to prevent moisture penetration from the bottom. Combined with the sealing boss on the top cover and the fluororubber sealing ring on the body, a double seal is formed, achieving an IP67 waterproof and dustproof rating. In humid environments, the capacitance decay rate is less than 3% after 1000 hours. Simultaneously, the porous structure formed by laser etching of the high-capacitance anode foil increases the specific surface area by 50-100 times compared to traditional anode foil. Combined with a conductive polymer composite electrode design, the capacitor can achieve a capacitance of over 1000μF within a φ10mm×20mm size, increasing the capacity per unit volume by over 40%. This makes it suitable for miniaturized, high-humidity applications such as consumer electronics and industrial control.

[0022] 2. This high-capacitance horn-shaped aluminum electrolytic capacitor with anode foil significantly enhances vibration resistance and safety through optimized mechanical structure and safety design. It overcomes the shortcomings of traditional equipment, such as easy breakage of the tabs and unstable explosion-proof threshold under vibration. The cathode foil tabs are fixed in both directions through the tab connecting seat on the base and the buffer sleeve on the top cover. Combined with the silicone buffer pad between the top cover and the horn-shaped terminals, it can absorb stress under random vibration, reducing the terminal torque attenuation rate from the traditional 3% to less than 0.5%. The explosion-proof weak area on the inner wall of the upper part of the capacitor body is designed as an annular groove structure with a thickness of only 30%-40% of the capacitor body wall thickness. The explosion-proof threshold error is controlled within ±5%. When the internal pressure rises sharply, it can crack and release pressure in a directional manner, avoiding shell breakage and electrolyte splashing. At the same time, the tab connecting seat adopts a combination of ceramic insulating substrate and copper conductive sheet, which not only ensures insulation but also reduces contact resistance, improving current conduction stability by 30%. It is suitable for high-vibration and high-safety scenarios such as vehicles and engineering machinery. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0024] Figure 1 This is an isometric schematic diagram of a high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to this utility model;

[0025] Figure 2 This is a schematic cross-sectional view of a high-specific-capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to this utility model;

[0026] Figure 3 This is a schematic cross-sectional view of a high-specific-capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to this utility model;

[0027] Figure 4 This is a front view schematic diagram of a high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to the present invention.

[0028] Reference numerals in the attached diagram: 1. Body; 2. Base; 3. Positioning protrusion; 4. Top cover; 5. Isolation paper roll; 6. Cathode aluminum foil; 7. High specific capacity anode foil; 8. Electrolyte; 9. Electrode tab connector; 10. Cathode foil tab; 11. Anode foil tab; 12. Explosion-proof weak zone; 13. Ceramic coating; 14. Sealing ring; 15. Sealing boss; 16. Perforation; 17. Buffer sleeve; 18. Buffer pad; 19. Horn terminal. Detailed Implementation

[0029] This section will describe in detail the specific embodiments of the present utility model. The preferred embodiments of the present utility model are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present utility model, but they should not be construed as limiting the scope of protection of the present utility model.

[0030] In the description of this utility model, it should be understood that the directional descriptions, such as up, down, front, back, left, right, etc., indicate the directional or positional relationship based on the directional or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0031] In the description of this utility model, terms such as greater than, less than, and exceeding are understood to exclude the stated number, while terms such as above, below, and within are understood to include the stated number. The use of terms like "first" and "second" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the quantity or sequence of the indicated technical features.

[0032] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0033] Please see Figure 1-4 This utility model provides a technical solution: a high specific capacitance horn aluminum electrolytic capacitor with anode foil, including a body 1, a base 2 fixedly connected to the lower part of the body 1, a positioning protrusion 3 fixedly connected to the lower part of the base 2, a top cover 4 fixedly connected to the upper part of the body 1, a sealing ring 14 fixedly connected to the upper end of the body 1, and a sealing protrusion 15 fixedly connected to the lower end of the top cover 4.

[0034] The positioning protrusions 3 under the base 2 can accurately align with the external installation station to avoid assembly misalignment;

[0035] Inside the apparatus 1, there is a roll of insulating paper 5. Outside the insulating paper 5, there is a cathode aluminum foil 6. Outside the cathode aluminum foil 6, there is a high specific capacity anode foil 7. Outside the high specific capacity anode foil 7, there is an electrolyte 8.

[0036] 5. The insulating paper, 6. the cathode aluminum foil, and 7. the high specific capacitance anode foil are wound together to form a conductive polymer composite motor unit;

[0037] A tab connecting seat 9 is fixedly connected inside the base 2. A cathode foil tab 10 is fixedly connected to the tab connecting seat 9. An anode foil tab 11 is provided on the opposite side of the cathode foil tab 10 inside the device body 1. An explosion-proof weak zone 12 is fixedly connected to the inner wall of the upper end of the device body 1. A ceramic coating 13 is provided on the base 2.

[0038] The sealing protrusion 15 at the lower end of the top cover 4 fits tightly with the sealing ring 14 at the upper end of the body 1 to form a primary seal, blocking external moisture and dust from entering; the ceramic coating 13 on the inner wall of the base 2 further isolates moisture penetration from the direction of the base 2, while preventing the internal electrolyte 8 from directly contacting the metal material of the base 2 and causing corrosion, ultimately forming a sealed, moisture-proof, and corrosion-resistant enclosed space inside the body 1.

[0039] The top cover 4 has two through holes 16 in the middle. A buffer sleeve 17 is fixedly connected inside the through holes 16. A buffer pad 18 is fixedly connected to the top cover 4. A pole tab connector 9 is fixedly connected to the buffer pad 18. A bull horn terminal 19 is fixedly connected to the pole tab connector 9.

[0040] The buffer sleeve 17 inside the perforation 16 of the top cover 4 wraps around the electrode tab, reducing friction and wear between the electrode tab and the metal material of the top cover 4, while preventing direct contact and short circuit between the electrode tab and the top cover 4, thus ensuring the stability of current conduction.

[0041] Working principle: First, the device constructs a stable internal working environment through a multi-layer structure, providing a basic guarantee for energy storage and conductivity. The device body 1 serves as the core outer shell, with its lower end fixedly connected to the base 2 and its upper end sealed to the top cover 4. The positioning protrusion 3 under the base 2 can accurately align with the external installation position to avoid assembly misalignment. The sealing protrusion 15 at the lower end of the top cover 4 fits tightly with the sealing ring 14 at the upper end of the device body 1, forming a primary seal to prevent external moisture and dust from entering. The ceramic coating 13 on the inner wall of the base 2 further isolates moisture penetration from the direction of the base 2, while preventing direct contact between the internal electrolyte 8 and the metal material of the base 2, which could lead to corrosion. Ultimately, this creates a sealed, moisture-proof, and corrosion-resistant enclosed space inside the device body 1, providing conditions for the stable operation of the electrode assembly and the electrolyte 8.

[0042] Secondly, the conductive polymer composite electrode assembly inside the device 1 is the core of achieving high specific capacitance energy storage. This electrode assembly is composed of insulating paper 5, cathode aluminum foil 6, and high specific capacitance anode foil 7 wound together. The insulating paper 5 serves as an insulating medium, separating the cathode aluminum foil 6 and the high specific capacitance anode foil 7 to prevent direct contact and short circuits between the two electrodes. The high specific capacitance anode foil 7, with its microporous etched structure, can significantly increase the charge storage capacity per unit volume, which is key to its high specific capacitance characteristics. The cathode aluminum foil 6 acts as a charge collection carrier, forming a corresponding pair with the high specific capacitance anode foil 7. The electrolyte 8 filling the electrode assembly provides ion conduction channels. When the capacitor is connected to the circuit, ions in the electrolyte 8 migrate to the two electrodes under the action of the electric field, forming charge accumulation on both sides of the oxide film on the surface of the high specific capacitance anode foil 7, thus achieving energy storage. Furthermore, the porous structure of the high specific capacitance anode foil 7 can significantly increase the charge accumulation area, enabling the capacitor to still have high capacity in a compact volume.

[0043] The current forms a complete conduction loop through the electrode and terminal structure, realizing the input and output of electrical energy. When the external circuit is connected to the horn terminal 19 on the top cover 4, the current is transmitted through two paths: one path is external circuit → horn terminal 19 → electrode connection seat 9 on the top cover 4 → cathode foil electrode 10 → cathode aluminum foil 6, and the other path is external circuit → another horn terminal 19 → electrode connection seat 9 on the top cover 4 → anode foil electrode 11 → high specific capacitance anode foil 7;

[0044] The charge collected by the two aluminum foil electrodes completes the charge-discharge cycle through ion migration in the electrolyte 8. The electrode connecting seat 9 in the base 2 serves to fix the cathode foil electrode 10 at the bottom and assist in conduction. This not only prevents poor contact caused by vibration and displacement of the cathode foil electrode 10, but also diverts some current and reduces the overall contact resistance. The buffer sleeve 17 in the perforation 16 of the top cover 4 wraps around the electrode, reducing friction and wear between the electrode and the metal material of the top cover 4, while preventing direct contact and short circuit between the electrode and the top cover 4, thus ensuring the stability of current conduction.

[0045] The equipment achieves dual protection of environmental adaptability and safety through structural design. The buffer pad 18 between the top cover 4 and the bullhorn terminal 19 can absorb external vibrations, such as random vibrations in vehicle and industrial settings, and disperse the stress at the root of the bullhorn terminal 19 to prevent the welding point between the terminal and the electrode connection seat 9 from breaking, ensuring uninterrupted current conduction. The explosion-proof weak zone 12 on the inner wall of the upper end of the device body 1 serves as a safety pressure relief structure. When the internal pressure of the capacitor rises suddenly due to abnormal conditions such as overcharging or high temperature, the explosion-proof weak zone 12 will deform and crack first, quickly releasing the internal pressure and preventing the entire device body 1 from breaking or the electrolyte from splashing, thus ensuring safe use.

[0046] Structural Description:

[0047] The capacitor body 1, as the core outer shell of the capacitor, is mainly used to support the base 2, top cover 4, and all internal components such as electrode groups and electrolyte 8. It also provides a fixing and installation benchmark for each component. It can form a unified structural framework to isolate the fragile internal electrode groups and electrolyte 8 from external impacts and dust, preventing damage to the core components from external collisions. Moreover, the rigid structure of the capacitor body 1 can ensure the accurate installation position of each component, prevent electrode short circuits or sealing failures caused by structural deformation, and provide basic support for the overall stable performance of the capacitor.

[0048] The base 2 is fixedly connected to the lower end of the body 1. Its main function is to support the body 1 and all internal components, and at the same time provide installation space for the tab connection seat 9. The rigid support of the base 2 allows the capacitor to be placed stably on the external installation position, avoiding wear or corrosion caused by the body 1 directly contacting the installation surface. In addition, the installation space inside the base 2 can fix the bottom of the cathode foil tab 10, forming a foundation for fixing the tab in both the upper and lower parts, solving the problem of easy vibration and displacement of the traditional tab when only the top is fixed, and improving the stability of the tab connection.

[0049] The positioning protrusion 3 is fixed at the lower end of the base 2. Its main function is to accurately align with the positioning slot of the external installation station. It can quickly realize the assembly and positioning of the capacitor, avoid positional deviation during manual installation, ensure that the installation angle and spacing of the capacitor in the equipment are consistent, and reduce poor connection between the horn terminal 19 and the external circuit due to positional deviation. It is especially suitable for batch assembly on automated production lines, which can shorten the assembly time of a single capacitor by more than 30% and improve production efficiency.

[0050] The top cover 4 is fixedly connected to the upper end of the body 1. Its main function is to seal the top of the body 1 and provide a mounting carrier for components such as the perforation 16, buffer pad 18, and electrode connecting seat 9. It works with the sealing ring 14 and the sealing boss 15 to form a top seal, preventing external moisture and dust from entering the body 1. At the same time, the planar structure of the top cover 4 can stably install the buffer pad 18 and the electrode connecting seat 9, providing a flat reference for the electrode to pass through and the horn terminal 19 to be fixed, thus taking into account both sealing protection and conductive connection functions, avoiding the problem that traditional top covers 4 cannot simultaneously achieve sealing and conductivity.

[0051] The sealing ring 14 is fixed to the upper end of the body 1 and corresponds to the sealing boss 15 of the top cover 4. Its main function is to enhance the sealing performance between the body 1 and the top cover 4. Through the elastic deformation of the sealing ring 14, it can tightly fill the gap between the body 1 and the top cover 4 to form a primary seal, effectively preventing external humid air and dust from entering the interior. Compared with traditional single epoxy resin seals, its moisture-proof effect is improved by more than 50%. In a humid environment of 95%RH, it can prevent the increase of leakage current caused by water vapor penetration within 1000 hours, thus improving the environmental adaptability of the capacitor.

[0052] The sealing boss 15 is fixed to the lower end of the top cover 4 and fits in correspondence with the sealing ring 14. Its main function is to cooperate with the sealing ring 14 to enhance the sealing pressure. The boss structure can be embedded in the sealing ring 14, increasing the contact area and compression pressure between the two, avoiding the sealing failure caused by vibration and aging of a single plane seal. At the same time, the boss can position the installation position of the sealing ring 14, prevent the sealing ring 14 from shifting, ensure uniform sealing effect, and further reduce the risk of leakage.

[0053] The insulating paper 5 is located on the innermost side of the device body 1 and is wrapped with cathode aluminum foil 6 on the outside. Its main function is to separate the cathode aluminum foil 6 from the high specific capacitance anode foil 7 to prevent the two electrodes from directly contacting and short-circuiting. As an insulating medium, it can block the direct conduction between the two metal electrodes while allowing ions in the electrolyte 8 to pass freely without affecting the ion conduction efficiency. At the same time, the thinness of the insulating paper will not occupy too much space in the device body 1, which is suitable for the design requirements of small volume and high capacity of capacitors and avoids the decrease in capacitance density due to excessive insulation layer.

[0054] The cathode aluminum foil 6 is wrapped around the outer side of the insulating paper 5. Its main function is to serve as a negative charge collection carrier, forming a bipolar correspondence with the high specific capacitance anode foil 7 to achieve charge separation and storage. The aluminum foil material has excellent conductivity, which can quickly collect the negative charges migrated from the electrolyte 8, reduce the current conduction resistance, and improve the charging and discharging efficiency. Moreover, the thin aluminum foil can be tightly wound with the high specific capacitance anode foil 7 to maximize the electrode area in a limited space, providing support for high-capacity energy storage.

[0055] The high-specific-capacitance anode foil 7 is wrapped around the cathode aluminum foil 6. Its main function is to increase the charge storage capacity per unit volume through its microporous etching structure, which is the core of the capacitor's "high specific capacitance" characteristic. The porous structure increases the specific surface area of ​​the anode foil by 50-100 times compared to ordinary aluminum foil, greatly increasing the charge accumulation area. It can achieve a capacity of over 1000μF in a compact size such as φ10mm×20mm, solving the problem of large volume caused by the low specific capacitance of traditional anode foil. At the same time, the porous structure allows the electrolyte 8 to be fully wetted, reducing capacity decay. At 105℃, the capacity decay rate can be reduced to less than 10% after 1000 hours, improving high-temperature reliability.

[0056] Electrolyte 8 is filled between the outer side of the high specific capacitance anode foil 7 and the inner wall of the container 1. Its main function is to provide an ion conduction channel to realize charge migration between the two electrodes. Ions in electrolyte 8 can move to the two electrodes under the action of electric field, and form charge accumulation on both sides of the oxide film of the high specific capacitance anode foil 7 to complete the storage and release of electrical energy. At the same time, electrolyte 8 can fully fill the porous structure of the anode foil to ensure uniform ion conduction, avoid capacity unevenness caused by insufficient local ion concentration, and ensure the stability of the capacitor charge and discharge cycle.

[0057] The electrode connector 9 is divided into two parts: one is fixed inside the base 2 and connects to the cathode foil electrode 10; the other is fixed on the buffer pad 18 of the top cover 4 and connects the cathode foil electrode 10, the anode foil electrode 11 and the horn terminal 19. Its main function is to fix the electrode and conduct current. The connector inside the base 2 can fix the bottom of the cathode foil electrode 10, forming a two-way fixation from top to bottom, avoiding poor contact caused by the electrode shifting due to vibration. The connector of the top cover 4 can realize the conductive connection between the electrode and the horn terminal 19. At the same time, its insulating substrate can prevent the electrode from short-circuiting with the metal top cover 4 and the device body, ensuring the safety of current conduction and reducing contact resistance.

[0058] The cathode foil tab 10 is connected at one end to the tab connector 9 of the base 2 and at the other end to the cathode aluminum foil 6. Its main function is to conduct the negative charge collected by the cathode aluminum foil 6. As a current channel, it can efficiently transfer the charge of the cathode aluminum foil 6 to the horn terminal 19. The bidirectional structure of bottom fixing and top connection can disperse vibration stress and avoid the problem of easy breakage of traditional tabs that are only fixed at the top. Under 10G random vibration, the terminal torque attenuation rate is reduced from 3% to less than 0.5%. At the same time, it can divert part of the current, reduce the overall conduction impedance, and improve the charging and discharging efficiency.

[0059] The anode foil tab 11 is located inside the body 1 on the opposite side of the cathode foil tab 10. One end is connected to the high specific capacitance anode foil 7, and the other end is connected to the tab connection seat 9 of the top cover 4. Its main function is to conduct the positive charge collected by the anode aluminum foil. The symmetrical layout with the cathode foil tab forms a complete current loop, ensuring efficient transfer of positive charge. The opposite arrangement can avoid short circuits between the two tabs, improving structural safety. At the same time, its conductive path is parallel to the cathode tab, which can balance the current distribution, reduce local heating, and avoid aging of the electrolyte 8 due to current concentration.

[0060] The explosion-proof weak zone 12 is fixed to the inner wall of the upper end of the body 1. It adopts a thinner wall thickness + annular groove design. Its main function is to safely release pressure when the internal pressure rises suddenly. When the capacitor is overcharged or the internal gas increases due to high temperature, and the pressure rises suddenly, the explosion-proof weak zone 12 will deform and crack first to quickly release the pressure and prevent the entire body 1 from breaking or the electrolyte from splashing. Compared with the traditional grooved explosion-proof structure, its explosion-proof threshold error is reduced from ±15% to ±5%, the pressure relief direction is controllable, and it can protect the surrounding components from electrolyte contamination and improve the safety of use.

[0061] The ceramic coating 13 covers the inner wall of the base 2, and its main function is to prevent moisture and corrosion. The ceramic material can block the moisture penetration from the direction of the base 2, solving the problem of traditional base 2 being unprotected and easily absorbing moisture. At the same time, it can isolate the internal electrolyte 8 from direct contact with the metal material of the base 2, avoiding corrosion of the base 2 caused by leakage of electrolyte 8. In a humid environment, the capacity decay rate is <3% after 1000 hours, extending the service life of the capacitor.

[0062] Two perforations 16 are located in the middle of the top cover 4, corresponding to the cathode foil tab 10 and the anode foil tab 11 respectively. Their main function is to provide a passage for the tabs to pass through, allowing the tabs to pass through the top cover 4 vertically, avoiding poor contact or breakage caused by bending of the tabs. The position of the perforation 16 corresponds precisely to the tab and the tab connecting seat 9, ensuring a smooth current conduction path and reducing the increase in impedance caused by path deviation. At the same time, it provides installation space for the buffer sleeve 17, taking into account both protection and conductivity requirements.

[0063] The buffer sleeve 17 is fixed inside the perforation 16 and tightly wraps the electrode tab. Its main functions are to buffer vibration and provide insulation protection. The silicone buffer sleeve 17 can absorb the vibration and friction between the electrode tab and the perforation 16, preventing the electrode tab from breaking due to long-term vibration and wear. At the same time, its insulation properties can prevent the electrode tab from directly contacting the metal top cover 4 and short-circuiting, ensuring stable current conduction. The interference fit design can further prevent external moisture from seeping in through the perforation 16 and enhance the overall sealing effect.

[0064] The buffer pad 18 is fixed on the top cover 4 and located between the top cover 4 and the electrode connector 9. Its main function is to absorb external vibration. The silicone buffer pad 18 can effectively absorb random vibration in vehicle and industrial settings, disperse the stress at the root of the horn terminal 19, and prevent the welding point between the terminal and the electrode connector 9 from breaking due to vibration. At the same time, it can compensate for the installation gap between the top cover 4 and the connector, ensure a tight connection, reduce contact resistance fluctuations, and ensure uninterrupted current conduction.

[0065] The bullhorn terminal 19 is fixed on the electrode connector 9 of the top cover 4. It adopts an L-shaped bend and a root reinforcing rib design. Its main function is to connect to the external circuit and transmit current. The bullhorn structure is suitable for industrial plug-in installation, which facilitates quick docking with the terminals of external equipment and improves assembly convenience. The one-piece molded reinforcing rib can enhance the strength of the terminal root and avoid terminal deformation caused by vibration. At the same time, its good conductivity ensures that the current is efficiently transmitted from the external circuit to the electrode to form a complete circuit, which is suitable for the needs of mass automated production.

[0066] The embodiments of the present utility model have been described in detail above with reference to the accompanying drawings. However, the present utility model is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present utility model.

Claims

1. An anode foil high specific volume cowhorn aluminum electrolytic capacitor comprising a body (1), characterized in that: The lower end of the device body (1) is fixedly connected to a base (2), the lower end of the base (2) is fixedly connected to a positioning protrusion (3), the upper end of the device body (1) is fixedly connected to a top cover (4), the inner side of the upper end of the device body (1) is fixedly connected to a sealing ring (14), and the lower end of the top cover (4) is fixedly connected to a sealing boss (15) corresponding to the position of the sealing ring (14), and the sealing boss (15) and the sealing ring (14) are sealed together. The device body (1) is provided with a separating paper (5), a cathode aluminum foil (6) and a high specific capacitance anode foil (7). The separating paper (5), the cathode aluminum foil (6) and the high specific capacitance anode foil (7) are wound to form a conductive polymer composite electrode group. The separating paper (5) is located on the inside, the cathode aluminum foil (6) is wrapped around the outside of the separating paper (5), and the high specific capacitance anode foil (7) is wrapped around the outside of the cathode aluminum foil (6). The high specific capacitance anode foil (7) and the inner wall of the device body (1) are filled with an electrolyte (8). An electrode connecting seat (9) is fixedly connected to the inner side of the base (2), and a cathode foil electrode (10) is fixedly connected to the electrode connecting seat (9). The other end of the cathode foil electrode (10) is connected to the cathode aluminum foil (6). An anode foil electrode (11) is provided on the side of the device body (1) opposite to the cathode foil electrode (10). One end of the anode foil electrode (11) is connected to the high specific capacity anode foil (7). The upper inner wall of the device (1) is circumferentially fixed with an explosion-proof weak zone (12), and the inner surface of the base (2) is covered with a ceramic coating (13). Two through holes (16) are provided in the middle of the top cover (4). A buffer sleeve (17) is fixedly connected in the through hole (16). The ends of the cathode foil tab (10) and anode foil tab (11) away from the electrode group pass through the buffer sleeve (17) in the corresponding through hole (16). A buffer pad (18) is fixedly connected at the upper end of the top cover (4) at the position corresponding to the through hole (16). A tab connecting seat (9) is fixedly connected on the buffer pad (18). A horn terminal (19) is fixedly connected on the tab connecting seat (9). The ends of the cathode foil tab (10) and anode foil tab (11) that pass through the through hole (16) are fixedly connected to the corresponding tab connecting seat (9).

2. The high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 1, characterized in that: The positioning protrusions (3) are provided in four parts and are evenly distributed along the lower end face of the base (2).

3. The high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 2, characterized in that: The sealing ring (14) is made of fluororubber and has a U-shaped cross-section. The cross-sectional shape of the sealing boss (15) is adapted to the U-shaped opening of the sealing ring (14), and the sealing boss (15) and the sealing ring (14) are interference fit.

4. The high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 3, characterized in that: The high specific capacity anode foil (7) has a porous structure formed by laser etching, and its surface is covered with a conductive polymer coating.

5. The high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 4, characterized in that: The electrode connector (9) includes a ceramic insulating substrate and a copper conductive sheet embedded in the substrate. The cathode foil electrode (10), anode foil electrode (11) and the copper conductive sheet are fixed by laser welding.

6. The high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 5, characterized in that: The thickness of the explosion-proof weak zone (12) is 40% of the wall thickness of the body (1), and its surface is provided with an annular groove.

7. The high specific capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 6, characterized in that: The buffer sleeve (17) is made of silicone, and its inner wall is provided with anti-slip texture. It is also press-fitted with the cathode foil tab (10) and the anode foil tab (11).

8. A high-specific-capacitance horn-shaped aluminum electrolytic capacitor with anode foil according to claim 7, characterized in that: The bullhorn terminal (19) is integrally die-cast from aluminum alloy, and an arc-shaped reinforcing rib is provided at its root. The buffer pad (18) is interference-fitted with the electrode tab.

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