Capacitor Module Planarity via Sacrificial Alignment

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Solution Overview

Problem

Solid electrolytic capacitor modules face issues with anode termination misalignment and non-planarity, leading to inadequate contact with the circuit board, which affects mechanical and electrical stability.

Innovation Solution

A solid electrolytic capacitor module design featuring a plurality of active capacitors and a sacrificial capacitor aligned in a horizontal direction, with a conductor connecting the cathode terminations, ensuring planarity and stability during assembly and mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If multiple solid electrolytic capacitors are incorporated into a single module to reduce area, then the area occupied by capacitors is reduced, but the anode termination ends become misaligned or non-planar during assembly

Engineering Contradiction:

Improvearea occupied by capacitor moduleVSAvoidplanarity of anode termination ends

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The invention divides the capacitor module into distinct segments: active capacitors, inactive capacitors, and a sacrificial capacitor. This segmentation allows each component to be positioned and aligned independently during assembly, ensuring that anode termination ends remain planar while still achieving compact area utilization through the modular structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sacrificial capacitor serves as an intermediary element during the assembly process. It is positioned between the active capacitors and the circuit board, providing a reference plane that ensures proper alignment and planarity of the anode termination ends. After serving its alignment function, the sacrificial capacitor is removed, having fulfilled its mediating role in achieving precise positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If anode termination ends are closely spaced in the module design, then area is reduced, but sufficient contact with the circuit board is not made due to non-planarity

Engineering Contradiction:

Improvearea occupied by capacitor moduleVSAvoidcontact integrity with circuit board

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The invention creates an equipotential reference plane using the sacrificial capacitor and the bottom surfaces of the inactive capacitors. This reference plane ensures that all anode termination ends are at the same height and orientation relative to the circuit board, providing uniform and reliable contact across all termination points while maintaining compact spacing.

Inventive Principle:

Principle #12Equipotentiality

Solution Approach 2:

The invention changes the physical state of the sacrificial capacitor from present to absent during the assembly process. The sacrificial capacitor is introduced to establish proper geometric parameters (planarity and alignment) during assembly, then removed after serving its function. This parameter change allows the system to achieve precise alignment without permanently occupying additional space.

Inventive Principle:

Principle #35Parameter changes

3Area of stationary object

If the conductor connecting cathode terminations runs down the side of the module, then area is reduced, but height variation affects connection integrity

Engineering Contradiction:

Improvearea occupied by conductorVSAvoidheight alignment of conductor with circuit board

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The conductor is positioned to connect with the reference plane established by the sacrificial capacitor and inactive capacitors. This reference plane provides a consistent height reference that ensures the conductor maintains proper alignment with the circuit board connection points, eliminating height variation issues while allowing the conductor to run efficiently down the side of the module.

Inventive Principle:

Principle #12Equipotentiality

Data Source

PatentUS10123425B2Solid electrolytic capacitor module with improved planarity

Publication Date: 2018.11.06 KYOCERA AVX COMPONENTS CORP

AI summary

A module containing a plurality of active capacitors and a sacrificial capacitor is provided. The active capacitors and sacrificial capacitor are aligned along a horizontal direction so that the side surfaces of their cases are parallel to each other. The particular arrangement of the active capacitors and sacrificial capacitor results in a module configuration where the anode terminations for the active capacitors and an external component of the lead frame for the sacrificial capacitor are coplanar so that the module can be mounted to a circuit board via the anode terminations and the external component of the lead frame in a mechanically and electrically stable manner. Further, the center of gravity of the module in the length and/or width directions can be located at a midpoint of the overall module length and/or width, which enhances the stability of the module when mounted to a circuit board.