Multilayer Solid Aluminum Capacitor Hermetic Case Assembly
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Solution Overview
Problem
Conventional multilayer solid aluminum electrolytic capacitors face reliability issues due to non-hermetic resin encapsulation, which allows moisture and corrosive gases to enter, leading to performance deterioration and failure, especially in harsh environments with high humidity and temperature.
Innovation Solution
A highly-reliable multilayer solid aluminum electrolytic capacitor design featuring an inorganic encapsulation case formed by welding a ceramic case with a cover plate, using a rivet to fasten axially symmetrical I-shaped cores, and applying insulating blocking adhesive to prevent deformation and delamination, ensuring better air tightness and core protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin encapsulation is used for cost-effective automated production, then manufacturing cost and productivity are improved, but hermeticity deteriorates allowing moisture and corrosive gases to enter the capacitor
Solution Approach 1:
The harmful resin encapsulation material is extracted and removed from the capacitor structure. The patent replaces resin encapsulation with a hermetic metal case structure, eliminating the source of moisture and corrosive gas ingress while maintaining automated manufacturing capabilities through the metal case assembly process
Solution Approach 2:
The encapsulation material parameter is changed from organic resin to inorganic metal materials. This fundamental material parameter change transforms the encapsulation from non-hermetic to hermetic, preventing moisture and corrosive gas penetration while allowing for automated production through standard metal case manufacturing processes
2Ease of manufacture
If resin encapsulation is used to protect the cores, then ease of manufacture is improved, but core deformation and delamination occur due to injection molding stress
Solution Approach 1:
The harmful injection molding process using resin is extracted and removed. The patent adopts a metal case structure that mechanically protects the cores without requiring injection molding, thereby eliminating the source of extrusion deformation and delamination while maintaining ease of manufacture through standard metal forming processes
Solution Approach 2:
A metal case structure is introduced as an intermediary protective element between the external environment and the cores. This metal case provides mechanical protection and stress distribution without the harmful effects of resin injection molding, preventing core deformation and delamination
3Ease of manufacture
If resin encapsulation is used for sealing, then ease of manufacture is improved, but leakage current and equivalent series resistance increase due to core extrusion
Solution Approach 1:
The harmful resin encapsulation process is extracted and removed. The patent replaces it with a metal case structure that provides sealing without core extrusion, thereby eliminating the cause of increased leakage current and equivalent series resistance while maintaining ease of manufacture through standard metal case assembly processes
4Ease of manufacture
If resin encapsulation is used to enclose the capacitor, then ease of manufacture is improved, but performance deterioration occurs due to resin shrinkage stress during curing
Solution Approach 1:
The harmful resin encapsulation process is extracted and removed. The patent adopts a metal case structure that eliminates curing shrinkage stress, thereby preventing performance deterioration while maintaining ease of manufacture through standard metal forming and assembly processes
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 provides enhanced reliability by preventing moisture ingress, reducing leakage current and equivalent series resistance, and maintaining performance stability in challenging environments, with improved air tightness and core protection through inorganic encapsulation and rivet-based assembly.
Implementation Method 1
a rivet; the plurality of cores are stacked in sequence, and fastened in the case through the rivet
Implementation Method 2
a rectangular connection part is connected between the anode part and the cathode part; upper and lower surfaces and two side surfaces of the rectangular connection part are each coated with an insulating blocking adhesive to form an insulating blocking tape
Implementation Method 3
an inorganic encapsulation case formed by welding a ceramic case with a cover plate
Data Source
AI summary
This application provides a multilayer solid aluminum electrolytic capacitor and a method for preparing the same. The multilayer solid aluminum electrolytic capacitor includes a plurality of cores, a rivet, a case, and a cover plate. The cores are stacked in sequence and fastened in the case through the rivet to form a semi-finished capacitor. The semi-finished capacitor is covered by the cover plate and then sealed to form the solid aluminum electrolytic capacitor.