Electrolytic Capacitor Sintered Base Electrode for Low ESR
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Solution Overview
Problem
Existing electrolytic capacitors face challenges in reducing manufacturing costs and yield due to low metal particle efficiency in base electrode formation, material loss, and increased ESR from surface oxidation, particularly in processes involving plating layers.
Innovation Solution
The use of a sintered metal base electrode formed by attaching metal nanoparticles to the anode and cathode surfaces and irradiating them with light to create a sintered metal connection, which enhances bonding and reduces material loss and oxidation, thereby improving manufacturing efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plating layer is used for the base electrode, then corrosion resistance is improved, but manufacturing cost increases and ESR increases due to surface oxidation
Solution Approach 1:
The patent removes the plating layer from the base electrode structure, extracting only the essential function of corrosion resistance through the sintered metal base electrode itself, thereby eliminating the additional manufacturing steps and costs associated with plating while reducing ESR
Solution Approach 2:
The patent changes the material parameters of the base electrode by using sintered metal with specific particle size distributions and density characteristics, achieving both corrosion resistance and low ESR through material composition optimization rather than through plating layers
2Ease of manufacture
If metal particles are used to form the base electrode, then material loss occurs during formation, but using alternative methods increases manufacturing complexity
Solution Approach 1:
The patent optimizes the particle size distribution and density parameters of the sintered metal base electrode to maximize metal particle efficiency during formation, reducing material loss while maintaining manufacturing simplicity through controlled sintering processes
Solution Approach 2:
The patent uses composite sintered metal structures with optimized particle size distributions that improve packing efficiency and reduce voids, thereby reducing metal particle loss during formation while maintaining ease of manufacture
3Strength
If the base electrode thickness is increased, then bonding strength is improved, but ESR increases due to surface oxidation
Solution Approach 1:
The patent optimizes the thickness parameter of the sintered metal base electrode to achieve the minimum required thickness for adequate bonding strength while minimizing the thickness that would expose more surface area to oxidation, thereby balancing bonding strength and ESR
Solution Approach 2:
The patent uses composite sintered metal structures with optimized density and porosity that provide high bonding strength at reduced thickness, minimizing the volume susceptible to oxidation while maintaining mechanical integrity
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 method results in an electrolytic capacitor with lower resistance and reduced manufacturing costs, while maintaining high yield and corrosion resistance, by utilizing a sintered metal base electrode that minimizes material loss and surface oxidation.
Implementation Method 1
irradiating them with light to create a sintered metal connection
Data Source
AI summary
An electrolytic capacitor includes a capacitor element including an anode part and a cathode part, an exterior body sealing the capacitor element, a first external electrode electrically connected to the anode part and exposed from the exterior body, a second external electrode electrically connected to the cathode part and exposed from the exterior body, and a first base electrode connecting the anode part and the first external electrode. The first base electrode contains a first sintered metal, and the first sintered metal is in contact with an end surface of the anode part not covered with the exterior body and is in contact with the first external electrode. A relation 0.5≤W1/Tpc≤100 is satisfied, where Wp represents a width of the end surface of the anode part, and Tpc represents a thickness of the first sintered metal at a center of the width Wp.