Solid Electrolytic Capacitor Fillet Formation via Preliminary Plating
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Solution Overview
Problem
Conventional lower-face electrode type solid electrolytic capacitors face challenges in improving volume efficiency and stable formation of fillet forming faces due to the need for additional volume increases and complex manufacturing processes, particularly in minimizing capacitor element size.
Innovation Solution
The solution involves forming plated anode and cathode fillet forming portions on the converting substrate's side end face, which are then cut to create concave portions or through holes, allowing for improved volume efficiency and stable fillet formation without the need for additional volume increases, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plating process is performed on the fillet forming face to improve solder wetting, then solder wetting is improved, but manufacturing process complexity and costs increase
Solution Approach 1:
The plating process is performed preliminarily on the entire terminal surface of the lower electrode before cutting. This preliminary plating action ensures that when the capacitor is later mounted and soldered, the fillet forming faces already have the plated surface necessary for good solder wetting, eliminating the need for post-cutting plating operations.
Solution Approach 2:
The terminal surface is segmented into different functional areas: the fillet forming faces that require plating for solder wetting, and other areas that do not. By plating the entire surface initially and then cutting to expose only the necessary plated areas for fillet formation, the solution selectively applies plating where needed while avoiding unnecessary plating elsewhere.
2Reliability
If concave portions are formed on electrode terminals with plating to create fillet forming faces, then fillet formation is improved, but volume efficiency of the capacitor element decreases
Solution Approach 1:
Instead of creating concave portions by removing material from the capacitor element body (which reduces volume efficiency), the invention forms fillet forming faces by cutting the substrate and exposing plated surfaces on the side end faces of the lower electrode. This dimensional approach creates the necessary fillet formation surfaces without compromising the capacitor element's volume efficiency.
Solution Approach 2:
The plated surfaces are extracted and exposed on the side end faces of the lower electrode by cutting the substrate. This extraction of plated surfaces to form fillet forming faces eliminates the need for concave portions within the capacitor element, thereby maintaining volume efficiency while still providing the plated surfaces needed for reliable solder fillet formation.
3Manufacturing precision
If additional plating processes are performed after cutting to form fillet forming faces, then soldering quality is improved, but manufacturing productivity decreases
Solution Approach 1:
The plating process is performed preliminarily on the entire terminal surface before any cutting operations. This preliminary plating eliminates the need for subsequent plating operations after cutting, thereby maintaining high manufacturing productivity while ensuring that the exposed surfaces after cutting have the necessary plated finish for quality soldering.
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 enhances the productivity and volume efficiency of the solid electrolytic capacitor by eliminating the need for concave portions within the capacitor's outer dimensions and stabilizing the formation of fillet forming faces, thus improving the overall manufacturing efficiency and capacitor performance.
Implementation Method 1
a plating process is performed on the fillet forming face
Data Source
AI summary
A solid electrolytic capacitor is provided in which volume efficiency of its capacitor element is improved. A converting substrate having an anode terminal forming portion and cathode terminal portion obtained by forming notches on faces exposed on outside faces of the anode and cathode portions and performing plating in the notches in portions in which the anode and cathode portions of a lower-face electrode type solid electrolytic capacitor is connected to the capacitor element and, after a sheathing resin is formed therein, the sheathed portion and converting substrate are cut along cutting planes to form fillet forming faces on the outside faces of the anode portion and cathode portion of the lower-face electrode type solid electrolytic capacitor.