Solid Electrolytic Capacitor Embedded Anode Lead Volumetric Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solid electrolytic capacitors face challenges in achieving high volumetric efficiency and capacitance due to the bulkiness of the anode lead frame assembly, which counteracts the compactness gained from the high surface area of the sintered anode.
Innovation Solution
A solid electrolytic capacitor design featuring a sintered, porous anode body with an embedded anode lead and a dielectric layer, where the anode lead extends from one surface and is connected to a metal plate via a conductive adhesive, with an insulating layer around the capacitor body to enhance volumetric efficiency and capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional anode lead frame assembly is used to support the anode lead, then the capacitor can be manufactured with standard processes, but the volumetric efficiency decreases due to the bulky lead frame structure
Solution Approach 1:
The patent extracts and eliminates the separate anode lead frame assembly from the capacitor structure. Instead of using a conventional lead frame to support the anode lead, the anode lead is directly embedded within the sintered anode body, removing the unnecessary lead frame components and thereby increasing volumetric efficiency while maintaining manufacturability through direct integration of functions.
Solution Approach 2:
The patent merges the anode lead support function with the anode body structure itself. By embedding the anode lead directly into the sintered anode body, the support function that previously required a separate lead frame assembly is now integrated into the anode structure, eliminating the bulky lead frame and improving volumetric efficiency.
2Volume of stationary object
If the anode lead is embedded within the sintered anode body, then the volumetric efficiency increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by embedding the anode lead into the anode body during the sintering process itself, rather than attempting to insert it afterward. The green compact is formed with the anode lead already in position, and the sintering process permanently secures it, simplifying the overall manufacturing process despite the integrated structure.
Solution Approach 2:
The patent utilizes the porous structure of the sintered anode body to accommodate and secure the anode lead. The porosity of the sintered material allows the anode lead to be embedded and held in place through the sintering process, achieving mechanical integration without requiring additional fastening steps or complex assembly procedures.
3Quantity of substance
If multiple solid electrolytic capacitor elements are assembled in a matrix, then the total capacitance increases, but the volumetric efficiency of the assembly decreases due to spacing and connection requirements
Solution Approach 1:
The patent merges multiple capacitor elements into a matrix assembly where the anode leads of adjacent elements are interconnected through the shared anode body structure. This integration eliminates the need for separate connection components and spacing between elements, allowing higher capacitance density while maintaining volumetric efficiency.
Solution Approach 2:
The patent applies multi-functionality by designing the anode body and lead structure to serve multiple functions simultaneously: each anode body provides capacitance for its own element while also serving as a connection structure for adjacent elements. The anode leads function both as electrical connections for individual elements and as interconnection elements for the matrix assembly, eliminating the need for separate connection components.
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
This configuration increases the volumetric efficiency and capacitance of the solid electrolytic capacitor while reducing equivalent series resistance (ESR), making it suitable for applications like SSDs and SIM cards.
Implementation Method 1
Conventional solid electrolytic capacitors are often formed by pressing a metal powder (e.g., tantalum) around a metal lead wire, sintering the pressed part
Implementation Method 2
anodizing the sintered anode
Implementation Method 3
applying a solid electrolyte to the anodically oxidized, sintered, porous anode body
Data Source
AI summary
A solid electrolytic capacitor that contains a capacitor element including an anode body, a dielectric layer, and solid electrolyte is provided. The capacitor element also includes an anode lead (e.g., wire, tape, etc.) that is electrically connected to the anode body. A first portion of the anode lead is embedded within the anode body, while a second portion of the anode lead extends from the anode body in a longitudinal direction. Contrary to conventional capacitors in which the exposed portion of the anode lead is supported by a complex and bulky lead frame assembly, there is no lead frame present in the capacitor of the present disclosure. Thus, the volumetric efficiency of the finished capacitor can be increased. An assembly containing a matrix of multiple solid electrolytic capacitor elements is also provided, as is a method for forming a matrix that comprises multiple solid electrolytic capacitor elements.