Capacitor Housing With Recessed Windings For High Power Density
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Solution Overview
Problem
Existing electrolytic capacitor designs are costly and inefficient in achieving high power density due to the need for separate housings for each winding and the use of expensive materials like aluminum.
Innovation Solution
A capacitor arrangement with a central housing support featuring recesses for multiple windings, allowing for a planar or connected configuration, using electrically insulating materials and contact elements for electrical connections, which also serves as a housing for the electrolyte, enabling compact and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate housings are provided for each winding, then each winding is properly protected and contained, but the device complexity and production cost increase
Solution Approach 1:
The patent combines multiple separate housing functions into a single common housing structure that accommodates multiple windings. The housing includes a bottom part, side walls, and a top part that collectively protect all windings, eliminating the need for individual housings for each winding while maintaining proper protection and containment.
Solution Approach 2:
The common housing structure serves multiple functions simultaneously: it contains multiple windings, provides mechanical protection, supports the separator, and facilitates electrical insulation. This multi-functional design reduces overall device complexity while maintaining reliability.
2Strength
If expensive aluminum housing material is used, then structural strength and electrical conductivity are ensured, but production cost increases
Solution Approach 1:
The patent employs composite material construction for the housing, combining plastic materials with metallic components only where absolutely necessary for electrical connection. The housing bottom part, side walls, and top part are primarily made from cost-effective plastic materials that provide sufficient mechanical strength and electrical insulation, replacing expensive aluminum while maintaining structural integrity.
3Reliability
If multiple separate housings are used for multiple windings, then each winding is independently protected, but the power density and packing efficiency decrease
Solution Approach 1:
By merging multiple windings into a single common housing structure, the patent achieves compact arrangement and high packing density. The windings are closely positioned within the housing with minimal spacing, maximizing the energy storage capacity per unit volume and thereby increasing power density.
4Device complexity
If contact elements perform both electrical contacting and housing-forming functions, then the device complexity is reduced, but the electrical insulation and contacting reliability may compromise
Solution Approach 1:
The patent segments the housing structure from the electrical contacting function. The housing (bottom part, side walls, top part) is made from electrically insulating plastic materials, while separate contact elements (first and second contact elements) are introduced specifically for electrical connection. This segmentation ensures that electrical insulation and contacting reliability are not compromised while maintaining simplified overall structure.
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 achieves high capacitance and power density while reducing material costs by eliminating the need for separate housings and expensive metals, allowing for simple and efficient electrical connections and increased packing density.
Implementation Method 1
The positive and negative electrodes of a winding are each electrically connected to a respective contact plate, in particular connected by pressure and/or welding.
Implementation Method 2
The positive and negative electrodes of a winding are each electrically connected to a respective contact plate, in particular connected by pressure and/or welding.
Implementation Method 3
the recesses accommodating the windings are each filled with electrolyte
Data Source
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AI summary
Arrangement having a housing which has at least one central housing part, in particular housing support, which has recesses, wherein in each case one winding, in particular capacitor winding, is arranged in a respective recess.