Bent Cathode Lead Structure for Reliable Electrolytic Capacitors
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Solution Overview
Problem
Existing electrolytic capacitors face challenges in enhancing reliability due to positional variations and electrical connectivity issues, despite improvements in reducing equivalent series resistance (ESR) and maintaining excellent frequency characteristics.
Innovation Solution
The electrolytic capacitor design includes a cathode lead terminal with multiple bent parts that are partially exposed, allowing for secure positioning and enhanced electrical connectivity through conductive adhesive placement, reducing ESR and improving reliability by facilitating accurate alignment and adhesion with the exterior body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cathode lead terminal is designed with multiple bent parts for positioning, then the positioning accuracy and electrical connectivity improve, but the device complexity increases
Solution Approach 1:
The cathode lead terminal is divided into multiple bent parts (first, second, third, and fourth cathode lead parts) that can be positioned at different heights and locations. This segmentation allows each part to serve specific positioning functions, improving manufacturing precision while managing complexity through functional division.
Solution Approach 2:
The cathode lead terminal extends in multiple dimensions with bent parts at different heights (controlled by parameter h) and positions. The fourth cathode lead part extends along the second main surface at a controlled height, creating a three-dimensional positioning structure that enhances alignment accuracy without requiring excessive planar complexity.
2Reliability
If the cathode lead terminal is exposed partially from the exterior body, then the electrical connectivity and adhesion improve, but the reliability may be affected by exposure to external factors
Solution Approach 1:
The exterior body selectively covers only certain portions of the cathode lead terminal while leaving other parts exposed. Specifically, the third cathode lead part is exposed from the exterior body to facilitate electrical connection, while the fourth cathode lead part is positioned at a controlled height to maintain adhesion. This local differentiation optimizes both electrical connectivity and protection from external factors.
Solution Approach 2:
The exterior body acts as an intermediary that selectively protects and exposes different parts of the cathode lead terminal. It provides environmental protection where needed while allowing electrical connection areas to remain accessible, thus mediating between the need for protection and the need for electrical connectivity.
3Manufacturing precision
If the fourth cathode lead part height is controlled to be less than or equal to height H, then the positioning accuracy improves, but the design constraints increase
Solution Approach 1:
The height of the fourth cathode lead part is controlled by specifying a parameter relationship (h ≤ H or h < H2) rather than fixing an absolute value. This parameter-based approach provides design flexibility while ensuring positioning accuracy, as the constraint can be adjusted based on specific application requirements without fundamentally changing the structure.
Solution Approach 2:
The height parameter h is designed to be adaptable within a range rather than fixed, allowing the fourth cathode lead part to be positioned dynamically at an optimal height that satisfies both positioning accuracy requirements and design constraints. This dynamic parameter approach enables optimization for different manufacturing and application scenarios.
Data Source
AI summary
An electrolytic capacitor includes a capacitor element, a cathode lead terminal, and an exterior body. The cathode lead terminal includes a first cathode lead part facing a first main surface of the capacitor element, a second cathode lead part bent from the first cathode lead part, a third cathode lead part bent from the second cathode lead part, and a fourth cathode lead part bent from the first cathode lead part. The second cathode lead part extends in a direction along a surface intersecting with the first main surface. The third cathode lead part extends to be exposed from the exterior body. The fourth cathode lead part extends along a second main surface of the capacitor element. In the normal direction of the first main surface, a height h of the fourth cathode lead part is less than or equal to a height H from the first cathode lead part to a portion of the third cathode lead part that is not exposed from the exterior body.