Capacitor Case Design With Patterned Grooves For Alignment
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Solution Overview
Problem
Compact high voltage electrolytic capacitors used in implantable medical devices face challenges with packaging efficiency due to the need for precise physical alignment and separation of anode and cathode components, which can lead to incomplete packaging and increased risk of device failure from physical and electrical breakdown.
Innovation Solution
A capacitor case design featuring a non-conducting cover, ring component, and plate with patterned grooves allows for efficient assembly and encapsulation of the material stack, including anode and cathode foils separated by a separator, within a non-conductive housing that maximizes energy density and minimizes the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical features are added to constituent components to assure precision of physical alignment, then reliability is improved, but packaging efficiency deteriorates
Solution Approach 1:
The housing is segmented into a cover portion and a base portion that can be separately assembled. The separator extends through both portions with engagement features that ensure precise alignment when the housing is assembled, eliminating the need for complex alignment features on individual capacitor components while maintaining packaging efficiency
Solution Approach 2:
The separator serves as an intermediary component that performs multiple functions: it electrically isolates adjacent foils, provides structural support, and includes engagement features that ensure precise alignment between the cover and base portions of the housing, thereby maintaining both reliability and packaging efficiency
2Reliability
If anodes maintain minimum distance from case wall, then reliability is improved, but packaging efficiency deteriorates
Solution Approach 1:
The separator is designed as a multi-functional component that provides electrical insulation between foils, structural support for the stack, and alignment features for the housing. This eliminates the need for separate insulation components and allows the anodes to be positioned closer to the case wall while maintaining reliable separation, thereby improving packaging efficiency
Solution Approach 2:
The functions of electrical insulation, mechanical support, and alignment are merged into a single separator component. This integration allows the capacitor assembly to be compacted more efficiently while maintaining the minimum distance requirements between anodes and case wall through the separator's engagement features
Data Source
AI summary
Designs of a capacitor housing and method of assembly are presented. A case for an electrolytic capacitor includes a non-conducting cover, a non-conducting ring component, and a non-conducting plate. The non-conducting cover has a patterned groove on a surface of the non-conducting cover. The non-conducting ring component has a shape that is substantially the same as a shape of the non-conducting cover, and is coupled to the non-conducting cover via the patterned groove of the non-conducting cover. The non-conducting plate has a shape that is substantially the same as the shape of the non-conducting cover, and has a patterned groove on a surface of the non-conducting plate. The non-conducting ring component is coupled to the non-conducting plate via the groove of the non-conducting plate.