SMD Capacitor Base Assembly for Shock-Resistant Mounting
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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, while maintaining electrical performance and dimensional constraints, and their manufacturing processes are cumbersome and inefficient.
Innovation Solution
A universal base for wet electrolytic capacitors is designed with a housing that includes recessed portions for contact pads and a conductive tab, allowing secure mounting and electrical coupling to lead wires, enhancing shock and vibration resistance, and simplifying manufacturing by reducing weld steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cylindrical shaped capacitors with axial leaded terminations are used, then reliability in harsh environmental conditions is improved, but energy density is limited due to cylindrical shape and limited surface area
Solution Approach 1:
The patent transitions from traditional cylindrical 3D geometry to a planar/flattened capacitor structure. The capacitor body is formed as a flat substrate with electrodes patterned on its surface, fundamentally changing the dimensional arrangement from volumetric to surface-based energy storage, thereby increasing surface area for given volume while maintaining structural integrity for harsh environments
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 capacitor structure is segmented into distinct functional layers: substrate layer, dielectric layer, electrode layers, and terminal structures. This segmentation allows each layer to be optimized independently - the substrate provides mechanical strength for harsh environments while the electrode patterns maximize surface area for energy density, resolving the contradiction between durability and energy storage capacity
3Reliability
If traditional manufacturing processes for wet electrolytic capacitors are used, then capacitor functionality is achieved, but manufacturing complexity is high with multiple weld steps
Solution Approach 1:
The patent combines multiple manufacturing operations into integrated process steps. The electrode formation, dielectric deposition, and terminal attachment are merged into a unified manufacturing sequence that eliminates separate welding steps. The terminal structures are directly formed from the electrode materials through pattern deposition and sintering, reducing the total number of discrete manufacturing operations while maintaining electrical functionality
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 base provides improved compatibility with different capacitor types, enhances energy density, and reduces manufacturing complexity, ensuring reliable operation in harsh environments and efficient mounting to electronic circuits.
Implementation Method 1
The capacitor dielectric material made by anodic oxidation of the anode material to form an oxide layer over the surface of the anode body
Implementation Method 2
A fluid electrolyte separates the cathode and the anode body and provides for electrical communication between the cathode and anode body
Data Source
AI summary
A capacitor is provided that includes a capacitor body and a surface mount device (SMD) base. The capacitor body includes a casing, a first lead wire, and a second lead wire. The base includes an electrical assembly, a housing formed around the electrical assembly, and first and second contact pads for electrically coupling to first and second lead wires of the capacitor body. The electrical assembly includes an electrical connector connected to the second lead wire, and a conductive tab from which the second contact pad is formed.