Rolled Electrolytic Capacitor Parallel Anode Cathode Segmentation
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Solution Overview
Problem
Conventional aluminum-rolled solid electrolytic capacitors face challenges in reducing equivalent series resistance (ESR) while maintaining stable capacitance, as the position of lead connections affects ESR variability, making it difficult to fabricate capacitors with consistent low ESR.
Innovation Solution
A rolled-type electrolytic capacitor design featuring multiple anode and cathode members with separator members, where each anode member has a dielectric coating and is electrically insulated, and cathode members are rolled together with separator members to achieve reduced ESR by mimicking the effect of multiple capacitor elements connected in parallel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple leads are connected to anode foil and cathode foil to reduce ESR, then equivalent series resistance decreases, but manufacturing stability deteriorates due to difficulty in maintaining constant connection positions
Solution Approach 1:
The patent divides the capacitor structure into multiple independent capacitor elements (first capacitor element and second capacitor element) with separate anode foils, cathode foils, and lead connections. Each element has its own lead tab terminals and leads, allowing multiple parallel connection paths without requiring precise positioning of multiple leads on single foils. This segmentation enables ESR reduction while maintaining manufacturing stability.
Solution Approach 2:
The patent combines multiple capacitor elements in parallel within a single capacitor body, merging their electrical paths through the external terminals. The first and second anode leads connect to the anode terminal, while first and second cathode leads connect to the cathode terminal, creating parallel current paths that reduce overall ESR without complicating the connection structure.
2Reliability
If multiple capacitor elements are connected in parallel to reduce ESR, then equivalent series resistance decreases, but device complexity increases
Solution Approach 1:
The patent nests multiple capacitor elements within a single capacitor body structure. The first and second capacitor elements are arranged concentrically or adjacently within the same housing, sharing common external terminals and electrolyte reservoir. This nesting approach reduces ESR through parallel connections while avoiding the complexity of multiple separate capacitor assemblies.
Solution Approach 2:
The patent uses common external terminals (anode terminal and cathode terminal) that serve multiple functions: they are the external connection points for the entire capacitor and simultaneously serve as the connection points for multiple internal capacitor elements. The electrolyte also serves all capacitor elements universally, eliminating the need for separate electrolyte systems for each element.
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 design effectively reduces equivalent series resistance to about half or one-third of conventional capacitors while maintaining capacitance, allowing for stable and consistent low ESR values.
Implementation Method 1
i (i is an integer not smaller than 2) anode members, j (j is an integer satisfying 1≦j<i) cathode members, and k (k is an integer not smaller than 2) separator members are rolled together
Implementation Method 2
i separator members are each arranged between adjacent anode member and cathode member, and rolled together with the i anode members and i cathode members
Data Source
AI summary
The electrolytic capacitor includes two chemically processed anode foils, two cathode foils, four separator sheets, four lead tab terminals, two anode leads and two cathode leads. The two chemically processed anode foils, two cathode foils and four separator sheets are arranged alternately and rolled, to form a capacitor element. Two lead tab terminals are connected to the two chemically processed anode foils, respectively, and the remaining two lead tab terminals are connected to two cathode foils, respectively. The two anode leads are connected to two lead tab terminals, respectively, and the two cathode leads are connected to two lead tab terminals, respectively. As a result, equivalent series resistance can stably be reduced.