Button-Shape Integrated Capacitor Molding for Compact Design
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Solution Overview
Problem
Existing capacitors have large height and weight, occupying significant space and lacking in anti-explosion performance, short circuit resistance, and anti-vibration performance, making them unsuitable for ultra-thin and lightweight electronic applications.
Innovation Solution
An integrated capacitor is created by integrally sleeving a capacitor core with a cover plate, followed by primary packaging, and then forming a sealing body between the cover plate and a shell through injection molding, resulting in an ultra-thin and lightweight capacitor with enhanced safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional capacitor structures are used, then the capacitor can provide sufficient capacitance, but the height and weight become large, occupying significant space
Solution Approach 1:
The patent integrates the capacitor core, cover plate, and sealing body into a unified structure where the cover plate is integrally formed with the sealing body through injection molding. This merging of components eliminates separate parts and reduces overall volume while maintaining the encapsulation function that provides anti-explosion performance.
Solution Approach 2:
The capacitor core is nested within the cover plate's inner cavity, which is itself nested within the sealing body. This nested arrangement allows compact packaging of components, reducing the overall height and volume of the capacitor while maintaining structural integrity and safety features.
2Length of stationary object
If capacitor size is reduced for ultra-thin applications, then the height and weight decrease, but the anti-vibration performance deteriorates
Solution Approach 1:
The sealing body is formed by injecting resin material that creates a composite structure encompassing the capacitor core and cover plate. This composite construction provides damping and structural support that enhances anti-vibration performance while maintaining the reduced height necessary for ultra-thin applications.
3Weight of stationary object
If the capacitor structure is simplified to reduce weight, then the manufacturing cost decreases, but the short circuit resistance performance worsens
Solution Approach 1:
The integration of the cover plate and sealing body into a single molded component reduces the number of separate parts and associated fastening elements, thereby reducing weight. Simultaneously, the molded structure provides continuous encapsulation of the capacitor core, maintaining effective short circuit resistance without requiring additional heavy components.
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 integrated capacitor achieves a significant reduction in height and weight while maintaining excellent anti-explosion performance, short circuit resistance, and anti-vibration performance, making it suitable for compact electronic devices.
Implementation Method 1
forming a sealing body between the cover plate and a shell through injection molding
Data Source
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AI summary
The disclosure relates to an integrated capacitor, which includes a shell (1), a sealing body, a cover plate (3), a capacitor core (4), a guide pin (9) and a positioning boss (8). The cover plate is provided with an inner cavity (10). The capacitor core is integrally sleeved in the inner cavity of the cover plate. The cover plate is provided with a through hole (7). The guide pin (9) passes through the through hole to protrude from an upper end surface of the cover plate. The positioning boss is fixedly arranged on the upper end surface of the cover plate. After being sleeved with the capacitor core, the cover plate is installed in the shell for packaging the cover plate. The sealing body is formed between the upper end surface of the cover plate and an opening of the shell by injection molding. The sealing body and the shell are integrally packaged. The guide pin and the positioning boss pass through the sealing body to protrude from the sealing body. The capacitor core is integrally sleeved with the cover plate and then subjected to primary packaging, and then the cover plate, the shell and the sealing body formed therebetween by injection molding are subjected to secondary packaging to produce the ultra-thin and lightweight integrated capacitor with high safety and desirable anti-explosion performance, short circuit resistance and anti-vibration performance, overcoming the defects of large height and weight and large space occupation in the traditional capacitors.