Capacitor Electrode Protrusion Laser Welding
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Solution Overview
Problem
The existing methods for connecting capacitor elements to external terminals through current collector plates face challenges in achieving accurate and robust welding, leading to increased resistance and potential incomplete connections due to variations in processing accuracy and gaps between contact faces.
Innovation Solution
The proposed solution involves a capacitor design where electrode protrusions are formed on the element end-face, connected to current collector plates, and welded to terminal members using laser or electron beam welding, with varied irradiation positions and a cover to ensure accurate contact and improved connection strength, regardless of the accuracy of the current collector plates and external terminal members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the clearance between capacitor elements and sealing members is increased to facilitate connection, then the ease of connection is improved, but the connection resistance increases and the capacitor height increases
Solution Approach 1:
The patent transitions from planar connection to three-dimensional connection by forming protrusions on the capacitor element end face that extend toward the sealing member. This vertical dimensionality change allows connection through the thickness direction, enabling reliable electrical connection without requiring large lateral clearance, thus reducing connection resistance while maintaining ease of connection.
Solution Approach 2:
The protrusions are formed in advance on the capacitor element end face before the sealing process. This preliminary formation of connection structures ensures that when the sealing member is applied, the electrical connection path is already established, facilitating easier connection while minimizing the required clearance and reducing connection resistance.
2Volume of moving object
If the clearance between capacitor elements and sealing members is decreased to make the capacitor compact, then the capacitor size is reduced, but the connection becomes troublesome and incomplete connection may occur
Solution Approach 1:
By utilizing the vertical dimension through protrusions that extend from the end face toward the sealing member, the patent achieves effective electrical connection within a compact lateral footprint. This allows the capacitor to be miniaturized in planar dimensions while maintaining reliable connection through the thickness direction.
Solution Approach 2:
The protrusions are nested within the limited space between the capacitor element body and the sealing member inner wall. This nested structure allows the connection elements to be accommodated within the compact overall dimensions of the capacitor, achieving both miniaturization and reliable connection.
3Strength
If laser welding is used to connect current collector plates and external terminals, then the connection strength is improved, but the welding accuracy requirements increase due to gaps between contact faces
Solution Approach 1:
The protrusions are formed in advance with predetermined dimensions and positions, establishing a pre-defined connection interface. This preliminary structuring ensures that when the sealing member with terminals is applied, the contact faces are properly aligned, reducing gaps and facilitating accurate laser welding while maintaining strong connections.
Solution Approach 2:
The patent controls the dimensions and positions of the protrusions as key parameters to optimize both connection strength and welding accuracy. By carefully designing the protrusion geometry (height, width, position), the patent achieves optimal balance between mechanical strength for laser welding and dimensional tolerance for accurate alignment, reducing the sensitivity to manufacturing variations.
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 approach reduces connection resistance, enhances the robustness and reliability of the connection, and allows for a more compact capacitor design while maintaining high welding accuracy and strength.
Implementation Method 1
at least one side face part of the terminal member is welded to at least one side face part of the current collector plate
Implementation Method 2
Laser welding or electron beam welding are used for this connection
Data Source
AI summary
A capacitor includes a capacitor element that is a wound element or an element other than the wound element, and that includes electrode bodies each of which is in an anode side and a cathode side, and separators that intervenes between the electrode bodies; a sealing member that seals an opening of a case member accommodating the capacitor element; at least one electrode protrusion that protrudes from one of the electrode bodies on an element end-face of the capacitor element, at least one of current collector plate that is connected to the electric protrusion; and at least one terminal member that is disposed in the sealing member, and is superposed on the current collector plate, a side face part of the terminal member being welded to a side face part of the current collector plate.