Capacitor Crimping Position Optimization for Vibration Resistance
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Solution Overview
Problem
Existing capacitor designs face issues with vibration resistance and reliability due to inadequate crimping positions, which can lead to damage of the capacitor element and terminal components, especially when crimping positions overlap with corner portions or end surfaces, resulting in incomplete fixation and potential damage to electrode foils and separators.
Innovation Solution
The capacitor is designed with crimping positions set at specific locations along the circumferential surface of the case, avoiding the end portions and corner areas of terminal components, and using a wrapping stop tape to buffer the crimping process, ensuring proper fixation and preventing damage to the electrode foils and separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimping positions are set to overlap with capacitor element and case for maximum fixation force, then vibration resistance is improved, but damage to terminal components and electrode foils occurs when crimping positions coincide with corner portions
Solution Approach 1:
The patent applies local quality by differentiating crimping positions into safe zones and dangerous zones. Crimping is performed at positions where the case and capacitor element overlap, but specifically avoids corner portions of terminal components. This localized differentiation of crimping quality (pressing force application) resolves the contradiction by maintaining fixation force where safe while avoiding damage where vulnerable.
Solution Approach 2:
The patent segments the crimping process into multiple discrete positions around the circumferential surface of the case. By dividing the crimping operation into several segmented locations rather than a continuous or single-position crimp, the invention can select specific segments that provide fixation without damaging terminal components, thus resolving the contradiction between fixation strength and component safety.
2Force
If crimping is performed at positions close to end surfaces of capacitor element, then fixation force is maximized, but incomplete overlap between case and capacitor element reduces fixing effectiveness
Solution Approach 1:
The patent applies parameter changes by optimizing the positional parameters of crimping locations. Specifically, it defines crimping positions in terms of angular or circumferential coordinates that ensure both adequate overlap between case and capacitor element and sufficient distance from end surfaces. This parameter optimization resolves the contradiction by finding the optimal balance point for fixation force and reliability.
3Reliability
If multiple crimping positions are used to improve vibration resistance, then fixation is enhanced, but complexity of crimping process increases
Solution Approach 1:
The patent applies partial action by selecting a specific number and arrangement of crimping positions that provides sufficient vibration resistance without implementing crimping at every possible location. This partial application of crimping (rather than comprehensive crimping) resolves the contradiction by achieving adequate fixation with reduced process complexity.
Data Source
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AI summary
A capacitor comprises a capacitor element having electrode foils on the anode side and the cathode side laminated via separators, connecting parts of terminal components being disposed inside a laminated portion of the electrode foils and the separators, the connecting parts being connected to the electrode foils on the anode side and the cathode side; and a case that includes a storage part storing the capacitor element and having an opening portion sealed by a sealing body, that has a crimped part crimped from the outside of the storage part toward a side surface of the capacitor element, and that holds the capacitor element with the crimped part. The case is crimped to form the crimped part while avoiding a position at which the electrode foils of the capacitor element in the storage part overlap with tip portions of the connecting parts of the terminal components. The vibration resistance of the capacitor element can be consequently improved to prevent a damage of the terminal components and achieve the stability of operation of the capacitor.