Solid Electrolytic Capacitor Anode Interface for Stronger Electrode Bonding

Solution Overview

Problem

Existing solid electrolytic capacitors face issues with low bonding strength between conductive layers due to the anchor effect, leading to peeling off and deterioration of electrical and mechanical characteristics.

Innovation Solution

A solid electrolytic capacitor design featuring a contact layer with a predetermined surface roughness on the anode terminal portion, formed using a cold spray method or alternative techniques, to enhance bonding strength and reduce contact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a smooth surface is used for the anode terminal portion, then the manufacturing process is simple, but the bonding strength between conductive layers is low causing peeling off

Engineering Contradiction:

Improvebonding strengthVSAvoidsurface treatment complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating surface roughness only on the anode terminal portion where the contact layer is formed, while keeping other areas smooth. This localized surface treatment increases bonding strength specifically at the electrode interface without complicating the entire manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements preliminary action by pre-forming the rough surface on the anode terminal portion before applying the contact layer. This preparatory surface treatment ensures optimal bonding conditions are established in advance, preventing peeling off of subsequent conductive layers.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If multiple conductive layers are stacked to improve electrical characteristics, then the electrical performance is enhanced, but the bonding strength between layers decreases leading to peeling off

Engineering Contradiction:

Improveelectrical characteristicsVSAvoidbonding strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies local quality by creating surface roughness only on the anode terminal portion where the contact layer is formed, while keeping other areas smooth. This localized surface treatment increases bonding strength specifically at the electrode interface without complicating the entire manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements preliminary action by pre-forming the rough surface on the anode terminal portion before applying the contact layer. This preparatory surface treatment ensures optimal bonding conditions are established in advance, preventing peeling off of subsequent conductive layers.

Inventive Principle:

Principle #10Preliminary action

3Strength

If the contact area between contact layer and anode-side electrode is increased, then the bonding strength and electrical characteristics are improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating surface roughness only on the anode terminal portion where the contact layer is formed, while keeping other areas smooth. This localized surface treatment increases bonding strength specifically at the electrode interface without complicating the entire manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements preliminary action by pre-forming the rough surface on the anode terminal portion before applying the contact layer. This preparatory surface treatment ensures optimal bonding conditions are established in advance, preventing peeling off of subsequent conductive layers.

Inventive Principle:

Principle #10Preliminary action

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 design improves electrical characteristics and mechanical strength by increasing the contact area and bonding strength between the contact layer and anode-side electrode, ensuring a reliable and efficient electrical path.

Implementation Method 1

a contact layer that is on an anode terminal portion, which is an end portion of the anode body, and has a surface with a predetermined surface roughness; and an anode-side electrode layer that covers the surface

Methodology Applied

Scientific EffectMechanical interlocking:

Data Source

PatentUS12586734B2Method of manufacturing solid electrolytic capacitor including exterior body that covers capacitor element

Publication Date: 2026.03.24 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A capacitor element that has an anode body, a dielectric oxide film layer covering the anode body, and a cathode body formed on the dielectric oxide film layer; an exterior body that covers the capacitor element; a contact layer that is on an anode terminal, which is an end portion of the anode body, and has a surface with a predetermined surface roughness; and an anode-side electrode layer that covers the surface are provided.