Solid Electrolytic Capacitor Assembly with Interlayer Thermal Conduction
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Solution Overview
Problem
High-frequency applications require capacitors with improved performance and size efficiency, but existing solid electrolytic capacitors tend to overheating due to insufficient power dissipation, especially when using finer tantalum particles that form 'necks' during sintering.
Innovation Solution
A capacitor assembly comprising two solid electrolytic capacitor elements with anodes made from valve metal compositions, such as tantalum or niobium oxide, and a thermally conductive material positioned between them to enhance heat dissipation, along with a case that exposes anode and cathode terminations for improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If finer tantalum particles are used to increase specific surface area and capacitance, then capacitance is improved, but necks form during sintering causing overheating
Solution Approach 1:
The capacitor is divided into multiple capacitor elements (first and second elements) with separate anodes. Each anode can be independently designed with optimal particle size and sintering characteristics, avoiding the neck formation problem while maintaining high capacitance through the combined surface area of multiple elements.
Solution Approach 2:
A thermally conductive material is introduced as an intermediary between the capacitor elements and the case. This material facilitates efficient heat transfer from the anodes to the case, preventing overheating while allowing the use of fine particles for high capacitance.
2Temperature
If multiple capacitor elements are assembled together, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
Multiple capacitor elements are merged into a single encapsulated assembly with common anode and cathode terminations. The elements are electrically connected in parallel through the lead frame, creating a unified component that functions as a single capacitor with improved heat dissipation capabilities.
Solution Approach 2:
The case serves multiple functions: it provides mechanical protection, electrical insulation, and thermal management through integrated heat dissipation pathways. The lead frame simultaneously provides electrical connections and structural support for multiple elements.
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 capacitor assembly effectively dissipates heat, allowing it to handle higher currents without overheating, resulting in improved electrical performance with reduced equivalent series resistance and increased capacitance, while maintaining a compact size.
Implementation Method 1
A thermally conductive material (e.g., metal) is positioned between the first and second solid electrolytic capacitor elements, wherein the thermally conductive material has a coefficient of thermal conductivity of about 100 W/m-K or more
Data Source
AI summary
An integrated capacitor assembly that offers improved performance characteristics in a convenient and space-saving package is provided. More specifically, the capacitor assembly contains a first solid electrolytic capacitor element and second solid electrolytic capacitor element positioned adjacent to the first solid electrolytic capacitor element. The first and second solid electrolytic capacitor elements each contain an anode formed from a valve metal composition having a specific charge of about 70,000 μF*V/g or more, the anode having a thickness of from about 0.1 to about 4 millimeters. A thermally conductive material is positioned between the first and second solid electrolytic capacitor elements and electrically connected thereto. The thermally conductive material has a coefficient of thermal conductivity of about 100 W/m-K or more at a temperature of 20° C. A case encapsulates the first and second solid electrolytic capacitor elements.