Solid Electrolytic Capacitor Terminal With Bent Extension Sections
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Solution Overview
Problem
The challenge is to reduce the size of solid electrolytic capacitors while maintaining high precision and reliability in connection, as smaller capacitors face difficulties in positioning and connecting the anode lead and terminal, leading to lower productivity and potential reliability issues.
Innovation Solution
The design includes an anode terminal with a middle section and extension sections that are bent nonparallel to the anode lead, allowing for improved positioning and connection reliability through a valley formed by the first and second main surfaces, enabling precise alignment and welding without load, thus enhancing the connection between the anode lead and terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the solid electrolytic capacitor is reduced in size to meet miniaturization requirements, then the capacitor can be mounted in smaller electronic devices, but the distance between the anode lead and anode terminal becomes shorter, making positioning and connection difficult and reducing productivity
Solution Approach 1:
The anode terminal is designed with extension sections that extend in directions nonparallel to the anode lead, creating a three-dimensional configuration. This allows the terminal to reach the anode lead even when the vertical distance is short, effectively adding horizontal positioning capability to compensate for reduced capacitor size.
Solution Approach 2:
The anode terminal includes bent extension sections with adjustable geometry, allowing the terminal shape to be optimized for different capacitor sizes and lead positions. This dynamic adaptability in terminal design maintains connection reliability across various miniaturization stages.
2Volume of moving object
If the connecting member is reduced in size to match the smaller capacitor, then the capacitor can be further miniaturized, but positioning with respect to the anode terminal and connection to the anode terminal become difficult, resulting in lower productivity
Solution Approach 1:
The anode terminal extends in multiple directions including nonparallel directions relative to the anode lead, creating a three-dimensional connection structure. This multi-dimensional configuration provides larger positioning margins and easier alignment even when overall component size is reduced.
Solution Approach 2:
The anode terminal is divided into a middle section and extension sections, with the extension sections specifically designed to reach the anode lead. This segmentation allows independent optimization of each section's geometry for both miniaturization and precise positioning.
3Volume of moving object
If the connecting member is reduced in size, then the capacitor can be miniaturized, but integral formation of the anode terminal and connecting member in high-precision becomes difficult, decreasing connection reliability
Solution Approach 1:
The anode terminal extends in directions nonparallel to the anode lead, creating a three-dimensional configuration that provides multiple contact points and redundant connection paths, thereby maintaining reliability even when the connecting member size is reduced.
Solution Approach 2:
The anode terminal and connecting member are integrated as a single component with the terminal including both the middle section and extension sections. This merging eliminates potential connection points of failure between separate components while maintaining precise geometry through single-piece manufacturing.
Data Source
AI summary
A solid electrolytic capacitor includes a capacitor element including an anode portion and a cathode portion, an anode terminal electrically connected to the anode portion. The anode portion includes an anode body and an anode lead extending from the anode body. The anode terminal includes a first main surface and a second main surface opposite to the first main surface. The anode terminal includes a middle section, a first extension section and a second extension section, the first extension section and the second extension section being respectively disposed at both sides of the middle section. The first extension section has a first end part and is bent so that a tip of the first end part faces the second main surface. The second extension section has a second end part and is bent so that a tip of the second end part faces the second main surface. The anode lead connects with the first main surface of the anode terminal at the first end part and at the second end part.