Multilayer Aluminum Electrolytic Capacitor Hermetic Ceramic Packaging
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Solution Overview
Problem
Conventional multilayer solid aluminum electrolytic capacitors are prone to failure due to moisture and corrosive gas ingress, core deformation, and performance deterioration under harsh conditions, limiting their application in complex environments with high reliability requirements.
Innovation Solution
A method involving the use of an inorganic encapsulation case formed by welding a ceramic case with a cover plate, incorporating an I-shaped core structure and riveting-welded anode parts, and filling the anode chamber with an insulating sealant to enhance air tightness and prevent core deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin encapsulation is used for low-cost and large-scale automated industrial production, then manufacturing cost and productivity are improved, but hermeticity deteriorates allowing moisture and corrosive gases to enter the capacitor
Solution Approach 1:
The patent changes the material parameter of the encapsulation from organic resin to inorganic material (glass or ceramic), which fundamentally alters the hermeticity characteristic while maintaining suitability for automated production processes
Solution Approach 2:
The patent employs composite encapsulation structures combining inorganic materials (glass or ceramic) with metal components to achieve both hermeticity and manufacturability, creating a multi-material system that resolves the contradiction between cost-effective production and environmental protection
2Ease of manufacture
If organic resin is used for encapsulation, then ease of manufacture is improved, but core deformation occurs due to resin entering the gap between cores during injection molding
Solution Approach 1:
The patent introduces a support structure as an intermediary element between the injection molding process and the core, preventing direct contact between resin and cores while still enabling the molding process to proceed, thus protecting core integrity during manufacturing
Solution Approach 2:
The patent uses a flexible support structure that can be positioned to prevent resin intrusion into core gaps during injection molding, allowing the molding process to occur without compromising core dimensional accuracy
3Ease of manufacture
If resin encapsulation is used, then ease of manufacture is improved, but leakage current and equivalent series resistance increase due to extrusion deformation of cores
Solution Approach 1:
The patent changes the encapsulation material from organic resin to inorganic material, which eliminates the chemical interaction and physical deformation causing increased leakage current and ESR, thereby improving electrical performance while maintaining manufacturability
4Ease of manufacture
If resin encapsulation is used, then ease of manufacture is improved, but performance deterioration occurs due to stress from resin shrinkage during curing
Solution Approach 1:
The patent changes the encapsulation material from organic resin to inorganic material (glass or ceramic), which has different thermal and mechanical properties that eliminate shrinkage stress during curing, thereby maintaining performance stability while preserving ease of manufacture through automated processes
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 solution provides a highly-reliable multilayer solid aluminum electrolytic capacitor with improved air tightness, preventing core deformation and enhancing bonding stability, suitable for complex environments with high reliability needs.
Implementation Method 1
performing anodizing on both surfaces of the aluminum foil to form a dielectric layer
Implementation Method 2
successively forming a conductive polymer solid electrolyte layer, a conductive carbon paste layer, and a silver paste layer on a surface of the cathode zone
Implementation Method 3
an inorganic encapsulation case which is formed by welding a case body with a cover plate
Data Source
AI summary
A method for preparing a stacked solid aluminum electrolytic capacitor is disclosed. The method includes preparation of a plurality of cores, stacking and fixing of the plurality of cores in a case and encapsulation of the case. The core is prepared through the following steps. An I-shaped aluminum foil is divided into an anode part and a cathode part by applying an insulating blocking tape, where the cathode part includes a dielectric layer, which is subjected to formation. A conductive polymer layer is formed on a surface of the cathode part, and is then impregnated with conductive colloidal graphite followed by drying to form a conductive carbon paste layer. The conductive carbon paste layer is impregnated with a conductive silver paste followed by drying to form a conductive silver paste layer. After that, a core is obtained.