Solid Electrolytic Capacitor Linear Through Conductor

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Solution Overview

Problem

The existing solid electrolytic capacitors suffer from degraded noise removal performance at high frequencies due to large parasitic inductances and resistances, low volumetric efficiency, and size limitations, primarily because of long conductive paths and non-linear contact surfaces between anode terminals and the anode wire.

Innovation Solution

A solid electrolytic capacitor design featuring a linear through conductor with a core and porous portions, a dielectric layer, and a conductive polymer cathode-side functional layer, where both end faces of the core are exposed to anode terminals for direct planar contact, reducing parasitic inductances and resistances, and utilizing a cylindrical shape for improved formability and sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional anode wire structure with bent anode terminals is used, then the capacitor can be manufactured with standard processes, but parasitic inductances become large and noise removal performance degrades at high frequencies

Engineering Contradiction:

Improvenoise removal performanceVSAvoidconductive path structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The anode terminal is segmented into a linear through-conductor portion and a bent terminal portion, with the linear portion providing a straight conductive path for low inductance and the bent portion providing mechanical flexibility for mounting. This segmentation allows the conductive path to be optimized for electrical performance while maintaining manufacturability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The anode terminal transitions from a purely planar bent structure to a three-dimensional structure with a linear through-conductor extending axially through the capacitor body, combined with bent terminal portions extending laterally. This dimensional change enables simultaneous optimization of electrical path length and mechanical mounting requirements.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Power

If long conductive paths are used in anode terminals, then the capacitor structure can accommodate bent terminals for mounting, but resistances become large and current flow is reduced

Engineering Contradiction:

Improvecurrent flow capabilityVSAvoidterminal mounting flexibility

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The anode terminal is divided into a linear through-conductor portion that provides a short axial path for low resistance, and a separate bent terminal portion that provides mounting flexibility. This segmentation allows the conductive path to be optimized for electrical performance while maintaining mechanical flexibility for mounting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The linear through-conductor acts as an intermediary that connects the internal capacitor structure to the external bent terminal portions, providing a low-resistance axial path while allowing the terminal portions to be optimized for mechanical mounting without increasing the electrical path length.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If non-linear contact surfaces are used between anode terminals and anode wire, then the capacitor can be assembled with flexible terminal configurations, but contact resistances increase and volumetric efficiency decreases

Engineering Contradiction:

Improveelectrical connection efficiencyVSAvoidcontact surface geometry

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

Instead of bending the entire anode terminal to achieve mounting flexibility, the invention inverts the approach by keeping the terminal portion that contacts the anode wire linear and axial, while allowing only the external terminal portions to be bent. This ensures optimal planar contact at the critical electrical interface while maintaining mounting flexibility where needed.

Inventive Principle:

Principle #13The other way round (Inversion)

4Volume of moving object

If conventional capacitor structures are used, then manufacturing processes are standard, but volumetric efficiency is low and size reduction is difficult

Engineering Contradiction:

Improvecapacitor sizeVSAvoidmanufacturing process complexity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The anode terminal adopts a three-dimensional structure with a linear through-conductor extending axially through the capacitor body, combined with bent terminal portions extending laterally. This dimensional change enables the terminal to pass through the capacitor body efficiently, reducing the overall footprint and improving volumetric efficiency while maintaining standard manufacturing processes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10629383B2Solid electrolytic capacitor

Publication Date: 2020.04.21 JAPAN CAPACITOR IND CO LTD

AI summary

A solid electrolytic capacitor that includes a capacitor element having a linear through conductor made of a valve function metal, a dielectric layer disposed on the through conductor, and a cathode-side functional layer disposed on the dielectric layer. The through conductor includes a core portion and a porous portion covering a peripheral surface of the core portion. Both end faces of the core portion of the through conductor are in contact with a pair of anode terminals on the pair of end faces of the body, respectively. A cathode terminal is electrically connected to the cathode-side functional layer.