Capacitor Busbar Structure for Smooth Lateral Element Insertion

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Solution Overview

Problem

The assembly of capacitors with busbars arranged in a horizontally flipped, rectangular C-like shape is hindered by structural complexities, leading to difficulties in inserting the capacitor element unit due to overlapping electrode terminals and protruding pieces that interfere with the insertion direction, causing poor workability and potential degradation of ESL and ESR.

Innovation Solution

The capacitor design incorporates elastically depressible connecting protrusions on the electrode terminals, allowing lateral insertion and absorption of tolerances, with protruding pieces formed in a vertically reversed checkmark-like shape to guide and smoothly insert the capacitor element unit, reducing interference and improving soldering performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the first busbar has an overhang that vertically overlaps the second electrode terminal, then the capacitor structure is compact and space-efficient, but the second busbar and capacitor element unit cannot be easily inserted from the upper direction

Engineering Contradiction:

Improvecapacitor structure compactnessVSAvoidinsertability of busbar and capacitor element unit

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The patent inverts the insertion direction from the conventional upper direction to the lateral direction. The capacitor element unit is inserted from the lateral side of the first busbar, bypassing the overhang obstacle. This directional inversion resolves the conflict between compact structure and ease of assembly.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the insertion dimension from vertical (upper direction) to lateral (horizontal direction). By moving the insertion path to another dimension that is not blocked by the overhang, the patent maintains compact structure while enabling easy assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If the capacitor element unit is inserted laterally through the opening, then the assembly is possible, but the protruding connecting pieces may interfere with and block the insertion path

Engineering Contradiction:

Improveinsertability of capacitor element unitVSAvoidinterference between protruding pieces and insertion path

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent performs preliminary action by bending the connecting pieces in a checkmark shape before assembly. This pre-positioning ensures that the protruding portions do not extend into the lateral insertion path, eliminating potential interference before the assembly process begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connecting pieces are formed with a curved checkmark shape instead of straight protrusions. This curvature directs the protruding portions away from the lateral insertion path, allowing smooth insertion while maintaining the electrical connection function.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If the connecting pieces are straight and protrude from the electrode terminal, then the electrical connection is direct, but they interfere with lateral insertion and increase assembly difficulty

Engineering Contradiction:

Improveelectrical connection qualityVSAvoidassembly workability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connecting pieces are formed with a curved checkmark shape instead of straight protrusions. This curvature maintains electrical connection reliability by ensuring contact with the electrode surface while directing the protruding portions away from the lateral insertion path, eliminating assembly interference.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The connecting pieces have different geometries at different locations: the base portion provides structural support and electrical connection, while the bent protruding portion provides tolerance absorption without interfering with assembly. This local differentiation resolves the conflict between connection reliability and assembly ease.

Inventive Principle:

Principle #3Local quality

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 enhances assembling workability by ensuring smooth insertion and firm soldering of electrode terminals, minimizing ESL and ESR, and maintaining product quality without altering the soldering jig.

Implementation Method 1

the first electrode terminal having a plurality of connecting protrusions the plurality of connecting protrusions being elastically depressible in response to contact with the first electrode surface of the capacitor element unit inserted from an opposite side

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4099352B1Capacitor and method for manufacturing same

Publication Date: 2026.01.28 NICHICON CORP

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AI summary

A second busbar is provided that has a second electrode terminal and a second connection terminal. A first busbar is provided that has a first electrode terminal, a lateral side coupler, an overhang, and a first connection terminal. The first electrode terminal and/or the second electrode terminal has a protruding piece for connection (connecting protrusion). This protruding piece is elastically depressible in response to contact with an electrode surface of a capacitor element unit inserted from an opposite side of the lateral side coupler across a space between the first and second electrode terminals.