Hermetic Electrolytic Capacitor Assembly for Shock and Vibration
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Solution Overview
Problem
Existing wet electrolytic capacitors face challenges in withstanding harsh environmental conditions such as extreme temperatures, pressure, moisture, shock, and vibration, leading to potential failure and increased maintenance costs, while also being limited by their cylindrical shape and surface area, which affects energy density and dimensional constraints.
Innovation Solution
The design includes a capacitor assembly with multiple anode plates and cathode assemblies, anode wire holders, a wire separator, and a glass-to-metal-seal, which securely positions anode plate wires and cathode foils within a case to enhance shock and vibration resistance, and allows for a low-profile configuration to fit within dimensional constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cylindrical shape with axial leaded terminations is used, then reliability in harsh environmental conditions is improved, but energy density is limited due to limited surface area
Solution Approach 1:
The patent transitions from a cylindrical shape with axial terminations to a rectangular or square-shaped capacitor body with radial leaded terminations. This dimensional change allows for increased surface area of the anode and cathode, thereby improving energy density while maintaining reliability through the robust rectangular structure that better withstands harsh environmental conditions.
2Quantity of substance
If circular or square shaped capacitors with radial leaded terminations are used, then energy density is improved, but ability to operate in harsh environmental conditions and survive shock or vibration is limited
Solution Approach 1:
The patent applies local quality by strategically positioning the leaded terminations at the radial ends of the rectangular or square-shaped capacitor body. This configuration optimizes the local structural properties to enhance both energy density through increased surface area and reliability by distributing mechanical stresses away from critical internal components, thereby improving shock and vibration resistance.
3Volume of moving object
If capacitor size is reduced to meet dimensional constraints, then mounting area and component profile are decreased, but shock and vibration resistance may be compromised
Solution Approach 1:
The patent employs composite construction techniques in the rectangular or square-shaped capacitor body, combining multiple materials with complementary properties. The body structure integrates materials that provide both compact dimensions and high mechanical strength, enabling the capacitor to maintain small size for meeting dimensional constraints while simultaneously achieving enhanced shock and vibration resistance through the synergistic properties of the composite materials.
Data Source
AI summary
A capacitor and capacitor assemblies are provided, configured to prevent damage from shock and/or vibration. A capacitor assembly according to the invention comprises an anode plate having an anode plate wire extending from a surface of the anode plate. An anode wire holder is positioned around at least a portion of the anode plate wire. A wire separator comprising a channel is provided, at least a portion of the anode plate wire received within the channel. Methods of forming capacitors and capacitor assemblies are also provided.