Stacked Electrolytic Capacitor Tab Crimping for Low-Resistance Connections
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Solution Overview
Problem
Existing methods for connecting cathode foils in stacked electrolytic capacitors are complex and can lead to reduced cathode foil area, increased contact resistance, and compromised capacitor characteristics due to difficulties in reliably bonding multiple thick or large tabs using welding.
Innovation Solution
The electrolytic capacitor employs a crimping structure formed by a metal anode connection part that penetrates through holes in anode tab groups, securely connecting multiple anode and cathode tabs to their respective lead members using a crimping structure, ensuring reliable and low-resistance connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect multiple anode tabs to the anode lead member, then electrical connection is achieved, but contact resistance increases significantly when there are many tabs or when tabs are thick
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a crimping process (mechanical deformation system). The anode lead member is crimped onto the anode tabs to form a mechanical interlocking connection, eliminating the need for welding. This substitution resolves the contradiction by providing reliable electrical connection without the high contact resistance associated with welding multiple thick tabs.
Solution Approach 2:
The patent changes the connection method from welding (thermal process) to crimping (mechanical process), altering the fundamental parameter of the joining process. This parameter change allows for low-contact-resistance connections even when connecting multiple thick tabs, as the crimping process creates intimate metal-to-metal contact without the oxide layer formation and heat-affected zone issues inherent in welding.
2Ease of manufacture
If through holes are formed in anode foils and cathode foils to connect tabs, then connection is achieved, but the area of cathode foils is reduced
Solution Approach 1:
The patent segments the connection function by forming through holes only in the anode foils where tabs are present, while leaving the cathode foils intact. The anode lead member is crimped onto the anode tabs through these holes, establishing electrical connection without requiring corresponding holes in the cathode foils. This segmentation approach enables easy manufacturing while preserving the full area of cathode foils.
3Reliability
If multiple thick tabs are connected by welding, then electrical connection is established, but the connection reliability is compromised due to increased contact resistance
Solution Approach 1:
The patent replaces welding with crimping to connect multiple thick tabs. The crimping process mechanically deforms the anode lead member to create a secure interlocking connection with the tabs, providing reliable electrical connection that scales well with the number and thickness of tabs. This mechanical substitution avoids the cumulative contact resistance issues that arise when welding multiple thick tabs.
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 enables reliable and low-resistance connections even with thick or numerous tabs, enhancing the capacitor's characteristics and performance.
Implementation Method 1
a portion of the anode connection part extending through the through hole HA and forming a crimping structure
Data Source
AI summary
An electrolytic capacitor including a plurality of anode bodies and cathode bodies, a plurality of anode tabs connected with the plurality of anode bodies, and an anode lead member connected to the plurality of anode tabs. The plurality of anode tabs include a first anode tab group and a second anode tab group. Each of the first and second anode tab group has a through hole Ha. The anode lead member includes a metal plate-shaped anode connection part, the anode connection part being connected to the first anode tab group and the second anode tab group. Each of the first and second node tab group is connected to the anode connection part using a first fixing structure. The first fixing structure is formed by a portion of the anode connection part extending through the through hole Ha and spreading out to form a crimping structure on the other side.