Solid Electrolytic Capacitor Anode Terminal Masking
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Solution Overview
Problem
Conventional solid electrolytic capacitors are prone to property deterioration and failure in high humidity environments due to metal ions migrating from the anode terminal, which can reach the solid electrolyte layer and dielectric film, increasing equivalent series resistance and leak current.
Innovation Solution
The anode terminal's predetermined section, which is prone to metal ion generation, is completely covered with a mask layer made of a second resin that is different from the outer insulation member's first resin, preventing water contact and ion migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anode terminal is exposed without additional coating, then the manufacturing process is simple, but metal ions elute from the anode terminal when contacted with water, causing property deterioration
Solution Approach 1:
The patent applies a mask layer made of resin to specific predetermined sections of the anode terminal where metal ion elution is most problematic, rather than coating the entire terminal. This localized approach provides targeted protection against humidity-induced metal ion migration while maintaining manufacturing efficiency and avoiding unnecessary complexity in non-critical areas.
Solution Approach 2:
The anode terminal is divided into predetermined sections that require protection and sections that do not. The mask layer is selectively applied to these predetermined sections, segmenting the protection strategy to focus resources on critical areas where metal ion elution poses the greatest risk to capacitor reliability.
2Reliability
If a single resin material is used for both outer insulation and anode terminal coating, then the manufacturing process is simplified, but the coating may not provide sufficient protection against metal ion migration
Solution Approach 1:
The patent employs a composite material system consisting of the outer insulation member made of one resin material and the mask layer made of a different resin material. This combination of different resin materials provides enhanced protection against metal ion migration by leveraging the complementary properties of each material, creating a more effective barrier system than a single material could provide.
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 solution effectively suppresses metal ion generation and migration, reducing property deterioration and enhancing the humidity resistance of the solid electrolytic capacitor.
Implementation Method 1
All surfaces of the predetermined section are completely covered with a mask layer made of a second resin except for the connection area
Implementation Method 2
The outer insulation member encases the capacitor element and a part of the cathode terminal
Data Source
AI summary
An outer insulation member made of a first resin packs a part of an anode terminal. The packed part of the anode terminal has a predetermined section. All surfaces of the predetermined section consist of a front surface, a back surface and edges connecting between the front surface and the back surface. The front surface includes a connection area. An anode lead wire is connected to the connection area while being not connected to the anode terminal other than the connection area. The all surfaces of the predetermined section are completely covered with a mask layer made of a second resin except for the connection area. The second resin is different from the first resin in at least one of composition thereof, content of an inclusion, size of an inclusion and shape of an inclusion.