Electrolytic Capacitor Closure Element Segmentation
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Solution Overview
Problem
Existing axial electrolytic capacitors face challenges in achieving reliable and efficient positive contacting, as the positive pole is typically a wire that requires laborious reworking for press-fit or SMD connections, and direct welding of contact plates onto large-area aluminum sheets is cumbersome.
Innovation Solution
The design incorporates a closure element with a conductive aluminum sheet that is shaped to fit within the capacitor housing, featuring a sealing element for insulation and an anode wire for temporary welding assistance, allowing for diverse contact shapes and secure anodal connections, including SMD and press-fit designs, while reducing inductance and enhancing vibration stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wire is used for positive contacting, then the capacitor can be manufactured with simple structure, but the wire requires laborious reworking for press-fit or SMD connections and has high inductance
Solution Approach 1:
The positive pole is segmented into two functional parts: a large-area aluminum sheet for welding and current distribution, and a separate contact element (wire, tab, or lamina) for flexible electrical connection. This segmentation allows the aluminum sheet to remain simple for manufacturing while the contact element provides versatility for different mounting methods (press-fit, SMD, welding).
Solution Approach 2:
The aluminum sheet acts as an intermediary between the capacitor's internal anode and the external contact element. It provides a large welding surface that facilitates reliable electrical connection while allowing the external contact element to have various shapes suitable for different mounting technologies, thus mediating between manufacturing simplicity and contacting flexibility.
2Reliability
If a large-area aluminum sheet is used for positive pole, then current distribution is improved, but direct welding of contact plate onto the sheet is very laborious
Solution Approach 1:
The positive pole structure is divided into a current-distributing aluminum sheet and a separate contact element. The aluminum sheet maintains its large-area configuration for optimal current distribution, while the contact element (attached via welding or other methods) provides a manageable interface for electrical connection, eliminating the laborious task of welding directly to the large sheet.
Solution Approach 2:
The contact element serves as an intermediary that bridges the large-area aluminum sheet and the external circuit. It maintains the electrical connection benefits of the large sheet while providing a practical, easily manufacturable interface for welding or other attachment methods.
3Ease of manufacture
If conventional sealing is used between closure element and housing, then assembly is simple, but vibration stability is insufficient
Solution Approach 1:
The sealing structure uses a composite design combining an elastomeric sealing element (such as rubber or silicone) with the rigid closure element and housing. The elastomeric material provides both effective sealing and vibration damping, while maintaining relatively simple assembly through compression or interference fit, thus achieving both assembly simplicity and vibration stability.
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 enables a flexible, long-lasting electrolytic capacitor with reduced inductance and resistance, capable of operating effectively at higher frequencies and withstanding higher peak currents, and provides improved vibration stability through the use of a sealing element and efficient current distribution.
Implementation Method 1
The sealing element serves for an electrically insulating connection between closure element and housing
Implementation Method 2
The anode wire is arranged, for example, welded on, at an outer side of the closure element
Data Source
AI summary
An electrolytic capacitor is disclosed. In an embodiment an electrolytic capacitor includes a housing having a base and an opening arranged opposite the base and a closure element being at least partly introduced into the opening, wherein the closure element is configured to close the housing, wherein the closure element includes a sealing element for electrically insulating a connection between closure element and housing, and wherein the closure element comprises at least one first contact element for electrically conductive connecting a second contact element.