Solid Electrolytic Capacitor Resin Cushioning for Molding Pressure
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Solution Overview
Problem
Solid electrolytic capacitors face deterioration in electrical characteristics due to compression and uneven pressure loads during injection molding and high-temperature environments, leading to increased ESR and LC values.
Innovation Solution
The capacitors are designed with a housing that allows resin filling between the capacitor elements, using cathode and anode resin-filling openings to cushion the cathode and anode lead-out layers, and incorporating ridged portions or a cushioning member to distribute pressure evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection molding is carried out using resin material without providing a gap between capacitor elements, then the housing can hermetically seal the capacitor elements, but the cathode layers and cathode lead-out layers are compressed and damaged due to pressure force on the outside surfaces
Solution Approach 1:
The patent applies preliminary action by providing gaps between capacitor elements before injection molding, and by forming resin-filling openings in advance. This allows the resin to be guided into specific locations where it can cushion the cathode layers during molding, preventing compression damage while maintaining hermetic sealing capability.
Solution Approach 2:
The patent uses resin as an intermediary substance that fills the gaps between capacitor elements and the housing. This resin acts as a cushioning medium that absorbs pressure during injection molding, protecting the cathode layers from compression damage while still allowing hermetic sealing of the entire assembly.
2Manufacturing precision
If capacitor elements are arranged on the cathode terminal at a wide interval, then compression between capacitor elements during injection molding is prevented, but the outer dimensions of the solid electrolytic capacitor increase
Solution Approach 1:
The patent applies local quality by providing gaps specifically at locations where compression damage is most likely to occur (between adjacent capacitor elements), while maintaining closer spacing in other areas. The resin-filling openings are strategically positioned to provide cushioning exactly where needed, allowing compact overall dimensions while protecting critical areas from compression damage.
Data Source
AI summary
A solid electrolytic capacitor having a plurality of capacitor elements is provided that is small in size and has good electrical characteristics. The solid electrolytic capacitor includes a plurality of capacitor elements each having a dielectric film, a cathode layer, and a cathode lead-out layer formed in succession on a surface of an anode body having an anode lead part, each anode lead part of the capacitor elements connected to an anode terminal, each cathode lead-out layer of the capacitor elements connected to a cathode terminal, and the plurality of capacitor elements covered by a housing made of resin. The capacitor elements 1 are mounted on the cathode terminal 2 at an interval, the cathode terminal 2 is provided with a cathode resin-filling opening 2a, and the resin is filled between the capacitor elements 1 and in the cathode resin-filling opening 2a. Alternatively, the capacitor elements 1 are mounted side by side on the cathode terminal 2 at an interval, a distance a between the capacitor elements 1 is substantially equal to a distance b from outside surfaces of outermost capacitor elements 1 among the capacitor elements 1 to an outside surface of the housing 9, and the resin is filled between the capacitor elements 1. Alternatively, the capacitor elements 1 are mounted side by side on the cathode terminal 2 at an interval, and the cathode terminal 2 is provided with ridged portions 10 between the capacitor elements 1. Alternatively, the capacitor elements 1 are mounted side by side on the cathode terminal 2 at an interval, and a cushioning member 11 is disposed between the capacitor elements 1.