Solid Electrolytic Capacitor Terminal Projection Forming

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Solution Overview

Problem

The existing manufacturing process for solid electrolytic capacitors is complicated and requires high accuracy due to the small diameter and length of the bolster member, leading to variations in anode lead attachment, affecting both appearance and performance.

Innovation Solution

The process involves forming anode and cathode terminals with projections or recesses using a rolling method with a large and small diameter portion, allowing for easier and more accurate attachment without the need for a bolster member, and filling the recess with synthetic resin to secure the terminals within the housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bolster member is used to connect the anode lead and anode terminal, then electrical connection is achieved, but the attachment process becomes complicated and requires high accuracy

Engineering Contradiction:

Improveelectrical connectionVSAvoidattachment process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention removes the bolster member from the structure entirely. Instead of using a separate cylindrical bolster member to bridge the height difference between the anode lead and anode terminal, the anode terminal itself is formed with an integrated projection that directly connects to the anode lead, eliminating the need for the external bolster component and simplifying the attachment process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the function of the anode terminal and the bolster member into a single integrated structure. The anode terminal is formed with a projection that combines both the electrical connection function and the height adjustment function, eliminating the need for a separate bolster member and reducing the number of components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a bolster member with small diameter and length is used, then electrical connection is achieved, but variations in attachment accuracy affect appearance and performance

Engineering Contradiction:

Improveelectrical connectionVSAvoidattachment accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention merges the anode terminal and bolster member functions into a single integrated component. The projection is formed as an integral part of the anode terminal through rolling, ensuring consistent dimensions and eliminating variability associated with separate small-diameter bolster members. This integration directly addresses the manufacturing precision issue by reducing the number of separate components that require precise attachment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The projection is formed in advance during the anode terminal manufacturing process through rolling, rather than being attached separately later. This preliminary formation ensures consistent dimensions and eliminates the need for high-precision attachment operations, directly addressing the manufacturing precision challenge.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If etching is used to form a projection on the anode terminal, then the bolster member attachment is avoided, but low etching accuracy in mass production causes projections with great variations in height

Engineering Contradiction:

Improveattachment processVSAvoidprojection height consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The invention replaces the chemical etching process with a mechanical rolling process to form the projection. Rolling provides superior dimensional control and consistency compared to etching, as it physically forms the projection with precise control over height and shape, directly addressing the manufacturing precision issue while maintaining the simplified attachment process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the manufacturing method from chemical etching to mechanical rolling. This parameter change in the formation process provides better control over the projection dimensions, ensuring consistent height and shape without the variations inherent in etching processes, thereby improving manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

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 improves productivity by reducing variations in terminal dimensions and attachment complexity, enhancing both appearance and performance consistency of the capacitors.

Implementation Method 1

anode terminal having a projection formed by rolling using a roll having a large diameter portion and a small diameter portion

Methodology Applied

Scientific EffectRolling: Roller

Data Source

PatentUS7854772B2Solid electrolytic capacitor and manufacturing method therefor

Publication Date: 2010.12.21 SANYO ELECTRIC CO LTD

AI summary

A solid electrolytic capacitor of the present invention includes a capacitor element having an anode member, a dielectric member, and a cathode member; an anode terminal attached to the anode member; a cathode terminal attached to the cathode member; and a housing for covering an outer periphery of the capacitor element, the anode terminal and the cathode terminal being each at least partly exposed from an undersurface of the solid electrolytic capacitor, the anode terminal having a projection formed by rolling using a roll having a large diameter portion and a small diameter portion, and being connected to the anode member at the projection.