Solid Electrolytic Capacitor Cold Spray Bonding
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Solution Overview
Problem
The existing solid electrolytic capacitors face challenges in downsizing, high cost due to complex assembly, and limited reduction of ESL (equivalent series inductance) due to mechanical joining issues between cured resin and metal, leading to potential peeling or breaking under stress after mounting.
Innovation Solution
A solid electrolytic capacitor design featuring a contact layer formed by high-speed metal particle collision for enhanced bonding between the anode terminal and exterior body, along with insulating and electrode layers, and external electrodes to ensure reliable electrical connections and reduced ESL.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical joining is used between cured resin and metal, then assembly is simple, but bonding strength is insufficient leading to peeling or breaking under stress
Solution Approach 1:
The patent replaces mechanical joining methods with a cold spray process that uses high-speed metal particle collision to form a metallurgical bond between the exterior body and anode terminal portion. This substitution of the joining mechanism achieves both strong bonding and assembly simplicity.
Solution Approach 2:
The patent changes the physical state and parameters of metal particles by accelerating them to high speed (supersonic or subsonic) before collision with the substrate. This parameter change enables the metal particles to penetrate the oxide layer and form strong metallurgical bonds, resolving the bonding strength issue while maintaining process simplicity.
2Reliability
If conventional welding is used to join anode comb terminal and anode electrode portions, then stable joining is achieved, but capacitor size increases due to required welding region
Solution Approach 1:
The patent replaces conventional laser welding with a cold spray process using high-speed metal particle collision. This eliminates the need for a separate welding region and enables direct joining at the interface between the anode comb terminal and anode electrode portions, achieving stable joining without increasing capacitor size.
3Reliability
If high-speed metal particle collision is used for bonding, then bonding strength is enhanced, but additional process step is required
Solution Approach 1:
The patent merges the bonding process with the sealing process by applying the cold spray process during the sealing stage when the exterior body is formed. This integration eliminates the need for a separate bonding process step, achieving enhanced bonding strength without increasing overall process complexity.
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 a solid electrolytic capacitor with high reliability and suitable electrical characteristics, enabling effective downsizing and reduced ESL while maintaining productivity and cost-effectiveness.
Implementation Method 1
contact layer forming for forming a contact layer by causing metal particles to collide with the anode terminal portion at high speed
Data Source
AI summary
A solid electrolytic capacitor having high reliability while maintaining suitable electrical characteristics, and a method for producing the same. The solid electrolytic capacitor includes a plurality of capacitor elements, an exterior body covering the plurality of capacitor elements, a contact layer metallic bonded to an anode terminal portion that is an end portion of the anode body, an anode-side electrode layer provided so as to cover the contact layer, a cathode-side electrode layer electrically connected to the cathode body, an anode-side external electrode provided on the surface of the anode-side electrode layer, and a cathode-side external electrode provided on the surface of the cathode-side electrode layer.