Casing-Less Capacitor Structure for Moisture Resistance and Low Weight
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Solution Overview
Problem
Capacitors face challenges in achieving both reduced weight and excellent moisture resistance, as existing designs often compromise on one aspect due to the use of exterior cases and mold resins which can absorb moisture.
Innovation Solution
A casing-less capacitor design featuring metal caps or a metal foil that cover the external electrodes and a capacitor element, along with a capacitor element protecting member and heat shrinkage tube, to prevent moisture absorption while eliminating the need for an exterior case, thereby reducing weight and enhancing moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an exterior case and mold resin are used to protect the capacitor, then moisture resistance is improved, but weight increases
Solution Approach 1:
The patent removes the exterior case and mold resin from the capacitor structure, extracting the harmful elements that caused both weight increase and moisture absorption. The capacitor element is left exposed without traditional protective housing, eliminating the source of the contradiction.
Solution Approach 2:
The patent applies a thin film coating (such as conformal coating or vapor-deposited layer) directly on the capacitor element surfaces. This thin protective film provides moisture barrier functionality without the bulk and weight of traditional exterior cases and mold resins.
2Strength
If an exterior case is used to protect the capacitor, then structural protection is improved, but weight increases
Solution Approach 1:
The patent eliminates the exterior case entirely, removing the heavy protective housing while relying on alternative lightweight protection methods such as thin film coatings and the capacitor element's own structural integrity.
Solution Approach 2:
Thin protective films are applied to the capacitor element surfaces, providing structural protection and environmental barrier without the weight penalty of rigid exterior cases. These films offer sufficient protection for most applications while maintaining lightweight design.
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
The solution effectively reduces the weight of capacitors by eliminating the exterior case and significantly improves moisture resistance by preventing direct contact between the external electrodes and air, thus extending the lifespan and performance of the capacitors.
Implementation Method 1
a pair of metal caps and/or a metal foil, the pair of metal caps each covering a corresponding one of the pair of external electrodes, the metal foil covering at least part of the capacitor element
Data Source
AI summary
A capacitor includes: a capacitor element; a pair of external electrodes provided at opposite ends of the capacitor element; and a pair of metal caps and or a metal foil, the pair of metal caps each covering a corresponding one of the pair of external electrodes, the metal foil covering at least part of the capacitor element.