Bent Tantalum Wire in Capacitor Body for Miniaturization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tantalum capacitors face challenges in miniaturization due to increased physical volume when attempting to enhance the usable area, which limits their size reduction.
Innovation Solution
The design includes a tantalum capacitor with a capacitor body and a tantalum wire where the insertion portion of the wire is bent inside the body and the non-insertion portion is outside, with a resin mold surrounding both, allowing for increased usable area without expanding the overall volume by optimizing the wire's geometry and bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the volume of the capacitor body is increased to enhance the usable area, then the capacitance is improved, but the physical volume of the capacitor increases, hampering miniaturization
Solution Approach 1:
The tantalum wire is inserted into the capacitor body and bent multiple times (first bending, second bending) to nest the wire within the available space. This allows the wire to occupy less external volume while maximizing its contact area with the capacitor body, thereby increasing the usable area without proportionally increasing the overall capacitor volume.
Solution Approach 2:
The tantalum wire is configured to extend in multiple dimensions rather than a single straight line. By bending the wire in multiple directions (first bending portion, second bending portion), the wire utilizes three-dimensional space more efficiently, increasing the usable area within the same volume envelope.
2Ease of manufacture
If the tantalum wire is bent outside the capacitor body to connect to the anode lead frame, then the connection is achieved, but the usable area inside the capacitor body is reduced
Solution Approach 1:
The tantalum wire is bent and nested within the capacitor body rather than extending outside. The first bending portion and second bending portion are configured to fit within the capacitor body's volume, maximizing the usable area while still achieving connection to the anode lead frame through the capacitor body's top surface.
Solution Approach 2:
The tantalum wire is divided into multiple segments with different functions: an insertion portion for contact, a first bending portion for spatial configuration, a second bending portion for connection, and a non-insertion portion for external connection. This segmentation allows each portion to be optimized for its specific function while maximizing overall space utilization.
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
This configuration results in a tantalum capacitor with a larger usable area ratio and maximum capacitance while maintaining the same external size, enhancing performance without increasing the physical volume.
Implementation Method 1
a capacitor body having a greater usable area to achieve miniaturization of the tantalum capacitor
Implementation Method 2
an oxidized tantalum Ta2O5 is formed by anode oxidization on a surface of tantalum which acts as an electrode metal
Implementation Method 3
a resin mold surrounding the capacitor body and the tantalum wire
Data Source
AI summary
A tantalum capacitor including: a capacitor body containing a tantalum powder and having a mounting surface; a cathode lead frame having the capacitor body mounted thereon; a tantalum wire having an insertion portion located inside the capacitor body and a non-insertion portion located outside the capacitor body; an anode lead frame connected to the non-insertion portion of the tantalum wire; and a resin mold surrounding the capacitor body and the tantalum wire, wherein the insertion portion of the tantalum wire has at least one bending.