Electrolytic Capacitor Terminal Anchoring for Higher Lead Strength
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Solution Overview
Problem
Existing electrolytic capacitors face challenges in achieving high terminal strength, which is crucial for reliable performance in electronic devices.
Innovation Solution
The electrolytic capacitor design includes anode and cathode lead terminals with terminal parts exposed on the bottom surface and two anchor parts extending from the terminal parts and embedded in the exterior resin. These anchor parts, with upright and extending parts, provide a high anchor effect, enhancing the terminal strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional lead terminals are used, then the structure is simple, but the terminal strength is insufficient
Solution Approach 1:
The lead terminal is divided into three distinct parts: a terminal part for electrical connection, an upright part for vertical support, and an extending part for lateral anchoring. This segmentation allows each part to perform its specific function optimally, with the extending part providing enhanced anchoring in the exterior resin to improve terminal strength.
Solution Approach 2:
The lead terminal structure transitions from a conventional single-level design to a multi-dimensional configuration with the upright part extending vertically and the extending part projecting laterally. This dimensional change creates a three-dimensional anchor effect that significantly enhances terminal strength while maintaining reasonable structural complexity.
2Reliability
If lead terminals with simple structure are used, then manufacturing is easy, but separation from exterior resin occurs
Solution Approach 1:
By segmenting the lead terminal into distinct functional parts (terminal part, upright part, extending part), the design achieves reliable attachment through the extending part's anchoring action while keeping each segment's manufacturing process relatively simple and compatible with conventional techniques.
Solution Approach 2:
The extending part acts as an intermediary element that mediates between the terminal part and the exterior resin, providing a mechanical anchor that prevents separation. This intermediary structure enhances reliability without requiring complex manufacturing processes.
3Strength
If anchor parts are added to lead terminals, then terminal strength increases, but device complexity increases
Solution Approach 1:
The anchor function is merged into the lead terminal structure itself by forming the extending part as an integral continuation of the upright part. This integration achieves enhanced terminal strength through anchoring while avoiding the complexity of separate anchor components and their associated assembly processes.
Solution Approach 2:
The lead terminal structure serves multiple functions: the terminal part provides electrical connection, the upright part provides vertical support, and the extending part provides lateral anchoring. This multi-functionality achieves improved terminal strength without requiring additional specialized components, thereby limiting the increase in overall device complexity.
Data Source
AI summary
An electrolytic capacitor includes a bottom surface and a top surface, and includes a capacitor element including an anode lead, an anode lead terminal and a cathode lead terminal each electrically connected to the capacitor element, and exterior resin 101. At least one of the anode lead terminal or the cathode lead terminal includes a terminal part exposed at the bottom surface, and two anchor parts each extending from the terminal part and embedded in the exterior resin. The terminal part includes a side end along a direction in which the anode lead extends. Each of the two anchor parts includes an upright part rising from the side end of the terminal part toward the top surface, and an extending part bending and extending from an upper end of the upright part.