Solid Electrolytic Capacitor Terminals From Single Metal Plate
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Solution Overview
Problem
The manufacturing of solid electrolytic capacitors with varying thicknesses and multiple laminated capacitor elements faces challenges in productivity and cost due to the need for individualized terminal designs and increased stress during welding, leading to potential cracks and high equivalent series resistance.
Innovation Solution
A solid electrolytic capacitor design featuring terminals formed from a single metal plate with specific geometries, including parallel extensions and bent parts, allows for versatile use across different thicknesses and lamination configurations, reducing the need for multiple punching dies and minimizing stress during welding by sandwiching the metal lead between arm parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anode terminal and cathode terminal are designed individually for each capacitor element thickness, then the electrical connection is optimized, but the manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent applies universality by designing a single standardized terminal structure that can be used across capacitor elements of different thicknesses. The terminal includes a pressing portion with a pressing surface that contacts the metal lead, and a lead-in portion that extends to the capacitor element. This standardized design eliminates the need to individually produce punching dies for each terminal type, thereby improving productivity while maintaining reliable electrical connection through the consistent pressing mechanism.
2Strength
If the anode connection piece is pressed with excessive pressure during welding, then the welding strength increases, but the metal lead bends and cracks may occur
Solution Approach 1:
The patent applies local quality by distributing the pressing force through a specifically designed pressing surface area on the pressing portion. Instead of concentrating force at a single point, the pressing surface provides localized contact that distributes stress evenly across the metal lead. This prevents excessive localized stress that would cause bending or cracking, while still achieving sufficient welding strength through the distributed pressure applied by the arm parts.
3Productivity
If the terminal structure is simplified for easier manufacturing, then productivity improves, but the adaptability to different capacitor element specifications decreases
Solution Approach 1:
The patent applies dimensionality change by designing the terminal with a three-dimensional structure that includes a pressing portion with pressing surface and a lead-in portion extending in different spatial directions. This dimensional design allows the terminal to accommodate capacitor elements of varying thicknesses while maintaining a standardized manufacturing process. The lead-in portion can extend to different lengths depending on the capacitor element thickness, providing adaptability without requiring different terminal designs.
Data Source
AI summary
A solid electrolytic capacitor includes a porous sintered body, a metal lead, a dielectric layer, a solid electrolyte layer, a first terminal, and a second terminal. The porous sintered body has a pair of main faces opposed to each other, a pair of side faces opposed to each other, and a pair of end faces opposed to each other. The metal lead is extended from one of the pair of main faces. The first terminal includes a first terminal mounting part extending in substantially parallel to each of the pair of side faces, and a pair of arm parts extending in substantially parallel to each of the pair of end faces. The pair of arm parts are opposed to each other. The second terminal includes a terminal connecting part electrically connected to the solid electrolyte layer. The metal lead is electrically connected to each of the pair of arm parts.