Solid Electrolytic Capacitor Low ESR via Dual Adhesive Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solid electrolytic capacitors face challenges in achieving low equivalent series resistance (ESR) due to limitations in the electrical connection between the cathode terminal and the cathode layer, which hinders their performance in high-performance electronic devices.
Innovation Solution
The proposed solution involves a solid electrolytic capacitor design where a first conductive adhesive is interposed between the first terminal component part and the third side surface of the element body, and a second conductive adhesive is applied between the second terminal component part and the second side surface, extending along the second side surface to reach the peripheral edge of the fourth side surface, enhancing the electrical connection and contact area between the cathode terminal and the cathode layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single conductive adhesive is used between the cathode terminal and the cathode layer, then the structure is simple, but the ESR cannot be reduced sufficiently
Solution Approach 1:
The cathode terminal is divided into two separate component parts (first and second terminal component parts) that are positioned at different locations on the element body. This segmentation allows each component to form its own conductive adhesive connection with the cathode layer, creating multiple parallel current paths that reduce overall ESR while maintaining structural manageability
Solution Approach 2:
The conductive adhesive connections are extended from a single-point or single-area connection to a multi-dimensional distribution across different surfaces of the element body. The first terminal component part connects to the third side surface while the second terminal component part connects to the second side surface, creating spatially distributed connections that reduce resistance
2Loss of energy
If the conductive adhesive contact area is increased, then the ESR is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The total conductive adhesive contact area is divided into two separate contact regions on different surfaces of the element body. This segmentation allows for more tolerant manufacturing processes at each individual connection point while achieving a larger total effective contact area, thereby reducing ESR without proportionally increasing manufacturing precision requirements
Solution Approach 2:
Different terminal component parts are positioned to contact different local regions of the cathode layer on different surfaces. This local distribution of contact areas allows each adhesive application to be optimized for its specific location, making the overall process more manufacturable while maintaining large total contact area for low ESR
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 design effectively reduces the equivalent series resistance (ESR) by increasing the contact area between the cathode terminal and the cathode layer, thereby improving the performance of the solid electrolytic capacitor.
Implementation Method 1
A first conductive adhesive is interposed between the first terminal component part and the third side surface of the element body. A second conductive adhesive is interposed between the second terminal component part and the second side surface of the element body.
Data Source
AI summary
A method of manufacturing a solid electrolytic capacitor includes steps (a) and (b). In the step (a), an element body is placed on a surface of a first terminal component part after applying a first conductive adhesive to the surface of the first terminal component part. The element body is placed with a third side surface of the element body facing the surface of the first terminal component part such that the first conductive adhesive is interposed between the third side surface of the element body and the first terminal component part. The step (b) is performed after the step (a). In the step (b), a second conductive adhesive is applied to fill space between a second terminal component part and a second side surface of the element body such that an opening is not filled with the second conductive adhesive.