Solid Electrolytic Capacitor Bent Terminal Manufacturing
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Solution Overview
Problem
Conventional solid electrolytic capacitors require multiple welding steps, which reduce productivity and can result in poor connections and terminal bending due to errors in bending angles during the manufacturing process, especially in capacitors with large widths.
Innovation Solution
The anode terminal is formed by bending a single metal plate to create a terminal part and an upright part, eliminating the need for welding and ensuring the upright part's base is securely coupled, allowing it to withstand resistance welding pressure without bending, with the upright part's height being shorter than the folded part to minimize positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welding steps are used to connect the connecting member to the anode terminal and the anode lead to the connecting member, then reliable electrical connections are achieved, but productivity is reduced and manufacturing complexity increases
Solution Approach 1:
The connecting member and anode terminal are merged into a single integral structure formed by bending the anode terminal plate. This eliminates the welding step between these two components while maintaining electrical connectivity, thereby improving productivity without compromising connection reliability.
Solution Approach 2:
The anode terminal is segmented into functional regions: the terminal body, the connecting member portion, and the support protrusion. This segmentation allows each part to perform its specific function while being formed as an integral structure, reducing welding steps while ensuring reliable connections.
2Productivity
If the belt part is bent vertically to the projection part to form the anode terminal, then the number of welding operations is reduced, but positional deviation occurs due to bending angle errors
Solution Approach 1:
The support protrusion is formed in advance on the anode terminal plate before the final bending operation. This preliminary structural feature provides a reference and support structure that guides the bending process and compensates for potential positioning deviations, ensuring accurate connection between the anode lead and terminal.
Solution Approach 2:
The support protrusion acts as a cushioning element that absorbs and compensates for bending angle errors. By providing this preliminary support structure, the design anticipates and mitigates positional deviations that would otherwise occur during the bending process, maintaining manufacturing precision while preserving productivity benefits.
3Ease of manufacture
If the belt part lacks sufficient coupling to the terminal forming part, then the bending process is simpler, but the belt part bends under resistance welding pressure
Solution Approach 1:
The support protrusion is formed in advance on the anode terminal plate to provide structural reinforcement at the critical connection point. This preliminary structural feature ensures that the connecting member portion has sufficient support to withstand resistance welding pressure without bending, while maintaining the overall simplicity of the manufacturing process.
Solution Approach 2:
The anode terminal plate has non-uniform thickness with a thicker support protrusion at the critical location and thinner regions elsewhere. This local quality variation provides enhanced strength and support where needed to prevent bending under welding pressure, while maintaining ease of manufacture in other areas through standard bending 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
This method increases productivity by eliminating unnecessary welding steps and reduces the likelihood of poor connections and terminal bending, even with errors in bending angles, thereby enhancing the reliability and efficiency of solid electrolytic capacitor manufacturing.
Implementation Method 1
anode terminal which includes a terminal part and a connecting member part formed by bending an anode terminal plate
Implementation Method 2
When forming the anode terminal by performing the bending process on one metal plate in such a manner, there is no need for welding between the anode terminal 103 and the connecting member 105
Data Source
AI summary
A solid electrolytic capacitor includes a capacitor element from which an anode lead projects forward and having a surface on which a cathode layer is formed, an exterior resin covering the capacitor element, and anode and cathode terminals including, respectively, an anode and cathode terminal surfaces which are exposed from a bottom surface of the exterior resin. The anode terminal is formed from one metal plate, and includes a terminal part forming the anode terminal surface, a folded part folded back at a side edge of the terminal part and arranged over a top surface of the terminal part, and an upright part bent vertically to the top surface of the terminal part at a front edge or a rear edge of a tip end part of the folded part. A tip end part of the anode lead is electrically connected to a tip end of the upright part.