Solid Electrolytic Condenser Parallel Anode Spacer Design
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Solution Overview
Problem
Existing solid electrolyte condensers face challenges in reducing equivalent series resistance (ESR), improving manufacturing efficiency, and minimizing welding imperfections due to complex bending processes and increased welding complexity.
Innovation Solution
A solid electrolyte condenser design featuring two condenser components connected in parallel along the thickness direction, with a conductive spacer connected to anode wires at both ends, reducing the number of welding processes and using a V-shaped trench portion for secure connections, and employing a sealing resin with glass frit for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two condenser components are connected in parallel laterally at one side of the cathode terminal with a bent anode terminal, then welding space is increased to avoid defective welding, but the condenser component cannot be made planar resulting in increased package size
Solution Approach 1:
The patent transitions from lateral connection (in-plane) to vertical connection (out-of-plane) by arranging condenser components in the thickness direction. This dimensional change allows the anode terminal to remain substantially planar while providing sufficient welding space through the vertical spacer structure, thereby reducing package size while maintaining welding quality.
2Area of stationary object
If two condenser components are connected in parallel in the longitudinal direction with spacers fixed by resistance spot welding, then the condenser component can be made planar ensuring sufficient connecting area, but the increased amount of welding reduces manufacturing efficiency and causes welding defects
Solution Approach 1:
The patent merges the spacer and anode terminal into a single integrated structure. This combination eliminates the need for separate welding operations to attach the spacer to the anode terminal, reducing the total number of welding processes from multiple spots to a single integrated welding operation, thereby improving manufacturing efficiency while maintaining sufficient connecting area.
3Adaptability or versatility
If spacers and anode terminal are formed as separate components requiring multiple welding processes, then connection flexibility is increased, but welding spots in close proximity cause deficient welding and strength degradation
Solution Approach 1:
The patent combines the spacer and anode terminal into a single integrated component, eliminating the need for multiple closely-spaced welding operations. This merger ensures sufficient distance between welding spots (or eliminates the issue entirely), preventing welding defects and strength degradation while maintaining connection flexibility through the integrated design.
4Shape
If complex bending processes are used to form spacers and anode terminal, then connection configuration is optimized, but the complicated process increases manufacturing complexity
Solution Approach 1:
The patent integrates the spacer and anode terminal formation into a single manufacturing step, eliminating the need for separate complex bending processes. The integrated structure is formed simultaneously, simplifying the manufacturing process while achieving the optimized connection configuration.
Data Source
AI summary
A solid electrolyte condenser includes two condenser components disposed along a first direction Z and connected in parallel. Each condenser component includes: a porous sintered body forming an anode; an anode wire having a portion being inserted into the porous sintered body; a dielectric layer covering the porous sintered body; and a cathode portion forming a cathode. The solid electrolyte condenser includes: a spacer, which is conductive and of which two ends in the first direction Z are respectively connected with the anode wires; an anode terminal, fixed to a side of the spacer that is opposite to the two condenser components; a cathode terminal, connected with each cathode portion at the two sides in the first direction Z; a sealing resin, covering the two condenser components; and an anode connection portion, fixed at the anode terminal of the spacer and formed along the first direction Z.