Solid Electrolytic Capacitor Cathode Lead Frame Local Quality Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solid electrolytic capacitors face challenges in miniaturization with increased capacitance while maintaining lead frame strength, leading to reduced volumetric capacitance efficiency and potential deformation during manufacturing.
Innovation Solution
The design incorporates a cathode lead frame with a thinner first part connected to the capacitor element and a thicker second part, along with an adhesive layer, to create a level difference, allowing for increased capacitor element volume and enhanced capacitance without compromising the lead frame's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the cathode lead frame is reduced to increase volumetric capacitance efficiency, then the capacitance per unit volume is improved, but the lead frame strength is reduced causing deformation during manufacturing
Solution Approach 1:
The cathode lead frame is designed with non-uniform thickness, having a first thickness in the region contacting the capacitor element and a second thickness in the region outside the exterior resin, where the first thickness is smaller than the second thickness. This local quality variation allows the interior region to maximize capacitance efficiency while the exterior region maintains structural strength and prevents deformation during manufacturing.
2Volume of moving object
If the thickness of the solid electrolytic capacitor is reduced for miniaturization, then the device size is improved, but the proportion of non-capacitance components increases reducing volumetric capacitance efficiency
Solution Approach 1:
The cathode lead frame employs different thicknesses in different regions: a thinner first thickness inside the exterior resin that maximizes the proportion of capacitance-forming materials, and a thicker second thickness outside the exterior resin that provides necessary structural support. This resolves the contradiction by allowing overall miniaturization while maintaining high volumetric capacitance efficiency through optimized local material distribution.
Data Source
AI summary
To provide a solid electrolytic capacitor capable of being miniaturized with larger capacitance. A solid electrolytic capacitor comprises a capacitor element, an anode lead frame, a cathode lead frame, an adhesive layer and an exterior resin. The anode lead frame is connected to an anode of the capacitor element. The cathode lead frame includes a first and a second cathode leads and a boundary part. The first cathode lead is connected to a cathode of the capacitor element by the adhesive layer. The boundary part is disposed between the first cathode lead and the second cathode lead so as to provide a level difference at the capacitor element side. The exterior resin covers the capacitor element, a part of the anode lead frame, a part of the cathode lead frame and the adhesive layer.