Laminated Solid Electrolytic Capacitor Layout for Misalignment Control
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Solution Overview
Problem
In the production of solid electrolytic capacitors with a laminate structure, the conductive paste used for interposing between capacitor elements causes misalignment during lamination, leading to inefficiencies.
Innovation Solution
The capacitor elements are laminated such that their anode and cathode portions face opposite directions, with the use of jigs to maintain alignment during curing, ensuring the edges are flush, thereby preventing misalignment and reducing equivalent series inductance (ESL).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive paste is used for lamination between capacitor elements, then electrical connection is achieved, but misalignment of capacitor elements occurs
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the conductive paste and capacitor elements. The resin layer has higher viscosity than the conductive paste, providing better positional holding capability during lamination, thereby preventing misalignment while maintaining electrical connection through the conductive paste embedded in the resin
Solution Approach 2:
The viscosity parameter of the bonding material is changed by combining resin and conductive paste. The resin component provides high viscosity for positional stability, while the conductive paste component ensures electrical conductivity. This parameter optimization resolves the contradiction between connection reliability and alignment precision
2Reliability
If capacitor elements are laminated in alternating orientation, then equivalent series inductance (ESL) is decreased, but misalignment occurs during lamination
Solution Approach 1:
The resin layer serves as a mediator that enables alternating orientation lamination while maintaining alignment. Its high viscosity prevents elements from shifting during the lamination process, allowing the ESL-reducing alternating pattern to be implemented without sacrificing manufacturing precision
3Reliability
If conductive paste is applied for lamination, then electrical conductivity is achieved, but misalignment and production inefficiency occur
Solution Approach 1:
The resin acts as a intermediary that improves production efficiency by preventing misalignment. This reduces rework and scrap rates, thereby increasing overall productivity while the embedded conductive paste maintains electrical conductivity
Data Source
AI summary
A plurality of capacitor elements laminated on top of another. The capacitor elements each including a first and second portion, where the first portion includes a first and second edge disposed opposite each other in a first direction D1 and at least a portion of the first portion forms a cathode portion, and the second portion projects from the first edge of the first portion and at least a portion of the second portion forms an anode portion. In one or more capacitor elements, the first edge is positioned at one side in direction D1, and the second edge is positioned at the other direction D1. In the remaining capacitor elements, the first edge is positioned at the other side in direction D1 and the second edge is positioned at one side in direction D1.