Solid Electrolytic Capacitor Planar Terminal Layout
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Solution Overview
Problem
Conventional solid electrolytic capacitors face manufacturing complexities and increased equivalent series resistance (ESR) or equivalent series inductance (ESL) due to the need for bending terminals and potential poor connections between separate connection parts and anode sections, which also lead to reduced occupancy of the capacitor element and increased ESR/ESL.
Innovation Solution
A solid electrolytic capacitor design where the anode and cathode terminals are formed integrally on an insulating substrate, with a connection part formed with the anode section, eliminating the need for separate connection parts and reducing the distance between the capacitor element and the electrodes, thereby increasing the connection area and improving the connection condition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the capacitor element is coated with an enclosure resin and terminals are bent along the outer peripheral surface, then the terminals can be connected to lower surface electrodes, but the capacitor element occupancy decreases and ESR/ESL increases due to increased terminal lengths
Solution Approach 1:
The patent transitions from a three-dimensional bent terminal configuration to a two-dimensional planar terminal layout on the insulating substrate. The terminals are formed on the same surface as the capacitor element rather than bending along the enclosure resin, reducing terminal length and improving electrical performance while maintaining connection functionality.
2Reliability
If separate pad members are used to connect the anode terminal to the anode section, then electrical connection is achieved, but the manufacturing process becomes complicated and connection reliability may decrease
Solution Approach 1:
The patent merges the anode terminal and anode section into a single integrated structure formed directly on the insulating substrate. This eliminates the separate pad member that was previously required, simplifying the manufacturing process while ensuring reliable electrical connection through the integrated design.
Solution Approach 2:
The anode terminal and anode section are formed in advance as an integrated structure on the insulating substrate before the capacitor element is mounted. This preliminary formation of the connection structure eliminates the need for subsequent pad member installation steps, simplifying manufacturing while ensuring connection reliability.
3Reliability
If the distance from the capacitor element lower surface to the lower surface electrodes is reduced, then terminal lengths decrease and ESR/ESL are reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent reduces the distance from the capacitor element lower surface to the lower surface electrodes by transitioning to a planar configuration where terminals are formed on the insulating substrate surface. This dimensional change eliminates the need for vertical enclosures and bent terminals, reducing terminal length and ESR/ESL while the integrated terminal formation simplifies the manufacturing process.
Data Source
AI summary
A solid electrolytic capacitor comprises an insulating substrate in which an anode terminal and a cathode terminal are formed. The anode terminal comprises a first anode section formed on a first surface of the insulating substrate, and a second anode section formed on a second surface of the insulating substrate, which are electrically connected to each other. The cathode terminal comprises a first cathode section formed on the first surface and a second cathode section formed on the second surface, which are electrically connected to each other. A distance between the first anode section and the first cathode section is smaller than a distance between the second anode section and the second cathode section. And an anode section and a cathode section of a capacitor element are electrically connected to the first anode section and the first cathode section respectively.