Capacitor Strip Arrangement with Angled Connecting Wires
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Solution Overview
Problem
Mini ceramic disc capacitors with round connecting wires are prone to deviation or falling during processing, leading to packaging failures and are not suitable for Surface Mount Technology (SMT) applications, resulting in low yield and increased costs.
Innovation Solution
A combination capacitor and strip material arrangement featuring a thin, flat ceramic disc capacitor with angled connecting wires that include a rear mounting part, a front contact part with series-connected contact surfaces, and a middle conducting part with an oblique and transverse extension, securely holding the capacitor element in place and facilitating SMT installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If round connecting wires are used to bond the capacitor element, then the capacitor can be manufactured with simple structure, but the capacitor element easily deviates or falls during processing leading to packaging failure
Solution Approach 1:
The connecting wire is transformed from a simple round wire into a structured component with a U-shaped configuration. The wire is bent to form a U-shape with two legs that clamp the capacitor element between them, creating a curved holding structure that prevents deviation and falling while maintaining manufacturing simplicity
Solution Approach 2:
The connecting wire structure is extended from a single-dimensional round wire into a two-dimensional U-shaped configuration. By bending the wire into a U-shape with vertical legs and a horizontal base, the structure creates a planar holding geometry that mechanically constrains the capacitor element in multiple directions simultaneously
2Adaptability or versatility
If connecting wires are suspended at one same lateral side relative to the capacitor element, then the capacitor is suitable for through-hole mounting, but it is not practical for SMT application requiring secondary processing to bend wires
Solution Approach 1:
The connecting wires are pre-formed into a U-shape configuration during the bonding process itself, with the legs extending in opposite directions from the capacitor element. This preliminary shaping eliminates the need for secondary wire bending operations in SMT assembly, as the wires are already positioned for direct surface-mount placement
Solution Approach 2:
The connecting wire structure is designed with flexible U-shaped geometry that allows the legs to extend in opposite directions, providing adaptability for different mounting orientations. The bent configuration enables the capacitor to be mounted directly on surface pads without requiring additional wire manipulation steps
3Volume of moving object
If mini ceramic disc capacitors are created for small-sized electronic products, then the capacitor size is reduced for micro substrate compatibility, but the capacitor element becomes prone to deviation and falling during processing
Solution Approach 1:
The connecting wires are bent into U-shapes with curved legs that wrap around and clamp the small capacitor element. This curved configuration creates a mechanical interlock that prevents the miniaturized capacitor from deviating or falling during handling and processing operations
Solution Approach 2:
The bonding structure combines the capacitor element with the U-shaped connecting wire assembly to form a composite unit. The wire structure acts as both an electrical conductor and a mechanical retaining feature, integrating support and connection functions into a single bonded assembly that prevents element separation
Data Source
AI summary
A combination capacitor and strip material arrangement includes a capacitor element, a strip material, and two connecting wires each including an angled rear mounting part fastened to the strip material, a front contact part providing two contact surfaces connected in series at a predetermined angle and attached to one of positive and negative electrodes of the capacitor element and a middle conducting part having angled portion connected to the angled rear mounting part and an inwardly and transversely extended extension portion connected to the front contact part. Thus, the capacitor element is firmly held down by the contact surfaces of the front contact parts of the two connecting wires for packaging, preventing the capacitor element from deviation, displacement or falling, and thus the capacitor yield can be greatly increased.