Solid Electrolytic Capacitor Lead Frame Interconnection
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Solution Overview
Problem
Existing solid electrolytic capacitor manufacturing techniques face issues with increased production costs, reduced yield due to variations in production, and reliability concerns caused by excessive pressure and adhesive displacement, leading to short-circuits and damaged components.
Innovation Solution
A solid electrolytic capacitor design featuring first and second lead frames connected by a third electrically conductive member, with a tilted connection surface angle and reduced thickness, and a method involving the deposition and setting of viscous conductive members to ensure reliable bonding without excessive pressure, thereby eliminating the need for additional connection members and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cathode lead frame and a supporting cathode lead frame are laser-welded together, then electrical connection is achieved, but production yield decreases when capacitor element thickness varies or increases
Solution Approach 1:
The patent introduces a third electrically conductive member as an intermediary between the first and second lead frames. This conductive member acts as a mediator that accommodates thickness variations of the capacitor element, ensuring reliable electrical connection without requiring precise laser-welding between the lead frames themselves, thereby maintaining high production yield.
Solution Approach 2:
The patent changes the connection method from direct laser-welding to adhesive bonding using electrically conductive adhesive. This parameter change in the connection technique allows for greater tolerance in capacitor element thickness variations, preventing connection failures and maintaining high production yield across different thickness specifications.
2Reliability
If electrically conductive adhesive is used to connect the lead frame to the capacitor element, then production cost increases, but electrical connection is achieved
Solution Approach 1:
The patent merges the functions of electrical connection and structural support into a single integrated lead frame structure with external exposure. This eliminates the need for separate additional connection members, reducing overall production cost while maintaining reliable electrical connection through the conductive adhesive.
3Productivity
If the capacitor element is rapidly transferred during mass production, then productivity increases, but the metal layer may be displaced from its predetermined position
Solution Approach 1:
The patent applies preliminary action by using a viscous electrically conductive adhesive that sets quickly upon application. This preliminary setting action occurs before the rapid transfer process, securing the metal layer in its predetermined position and preventing displacement during high-speed production operations.
4Reliability
If the cathode lead terminal is attached by sandwiching the capacitor element, then connection is achieved, but excessive pressure damages the capacitor element and squeezes out silver paste
Solution Approach 1:
The patent introduces a viscous electrically conductive adhesive as an intermediary between the cathode lead terminal and the capacitor element. This intermediary material distributes the connection pressure uniformly, preventing excessive localized pressure that would damage the capacitor element or squeeze out silver paste, while still achieving reliable electrical connection.
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
The solution achieves high production yield and reliability by ensuring secure connections between lead frames, preventing damage to the capacitor element and reducing the likelihood of short-circuits, while also lowering production costs and improving transfer efficiency.
Implementation Method 1
The first to third electrically conductive members are each deposited on the cathode portion
Implementation Method 2
the viscous electrically conductive members are set
Data Source
AI summary
A first lead frame has a cathode connection portion connected via a first electrically conductive member to a cathode portion, and a first connection portion having a first connection surface, and is at least partially, externally exposed. A second lead frame has a supporting connection portion connected via a second electrically conductive member to the cathode portion, and a second connection portion having a second connection surface facing the first connection surface. A third electrically conductive member interconnects the first and second connection portions. A solid electrolytic capacitor that can achieve low cost and high production yield can thus be provided.