Solid Electrolytic Capacitor Lead Frame Integration
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Solution Overview
Problem
Conventional solid electrolytic capacitors require an additional pillow member for electrical connection, leading to increased manufacturing costs and reduced production accuracy due to variable welding location and strength.
Innovation Solution
The design integrates a rising portion with a through hole in the anode lead frame, eliminating the need for a pillow member and allowing for accurate attachment of the capacitor element by alleviating stress and thermal distortion during welding, while the through hole serves as an anchor for the mold resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pillow member is used to electrically connect the anode portion and anode lead frame, then electrical connection is achieved, but manufacturing cost increases and attachment accuracy decreases
Solution Approach 1:
The patent merges the pillow member's electrical connection function directly into the anode lead frame by forming a conductive portion on the lead frame surface. This eliminates the separate pillow member component while maintaining the electrical connection between the anode portion and anode lead frame, thereby reducing device complexity without sacrificing reliability
Solution Approach 2:
The anode lead frame is designed to perform multiple functions: it serves as both the structural support and the electrical connection path. The conductive portion formed on the lead frame surface enables direct electrical connection to the anode portion, making the lead frame a multi-functional component that replaces both the structural and electrical roles previously fulfilled by separate components
2Reliability
If a pillow member is welded to the lead frame, then electrical connection is established, but manufacturing cost increases due to additional welding process
Solution Approach 1:
The patent combines the electrical connection function into the lead frame structure itself through a conductive portion formed on the surface. This eliminates the need for a separate welding process to attach a pillow member, simplifying the manufacturing process while maintaining reliable electrical connection
Solution Approach 2:
The invention extracts the electrical connection function from the pillow member and integrates it directly into the anode lead frame. By removing the pillow member component entirely and embedding the conductive function into the lead frame, the manufacturing process is simplified without compromising connection reliability
3Manufacturing precision
If the anode lead frame is designed with a rising portion for attachment, then attachment accuracy improves, but stress concentration occurs during welding
Solution Approach 1:
The patent applies local quality by creating a conductive portion with specific material properties at the exact location where electrical connection is needed. This localized conductive region on the anode lead frame surface provides both the necessary electrical conductivity and structural characteristics to distribute welding stress, preventing concentration at the rising portion while maintaining attachment accuracy
Data Source
AI summary
A solid electrolytic capacitor includes a capacitor element, an anode lead frame, a cathode lead frame, and a mold resin portion. The anode lead frame includes an anode terminal portion and a rising portion, and the anode terminal portion is exposed at the bottom surface of the mold resin portion. The rising portion is formed integral with the anode terminal portion, and rises to the anode portion. In the rising portion, a through hole is formed. The cathode lead frame includes a cathode terminal portion, a pair of side surface portions and a step portion. Thus, a solid electrolytic capacitor allowing highly accurate and reliable attachment of the capacitor element to the lead frame without using any additional member is provided.