Solid Electrolytic Capacitor with Stacked Anode Frames
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Solution Overview
Problem
Conventional solid electrolytic capacitors have a poor ESL (equivalent series inductance) characteristic due to long lead distances from the capacitor element to the terminals, which limits their application in high-frequency applications requiring smaller size, larger capacity, and improved noise removability and transient response.
Innovation Solution
The design involves a capacitor unit with a cathode frame coupled to the cathode part and anode frames on either side, with flat parts on the anode terminals and a central flat part on the cathode terminal, all covered with coating resin, to reduce lead distances and ESL.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead distance from the capacitor element to the terminal is long, then the capacitor can accommodate larger components and simpler terminal structure, but the ESL (equivalent series inductance) increases resulting in poor high-frequency performance
Solution Approach 1:
The patent transitions from a conventional linear lead arrangement to a three-dimensional stacked configuration where the capacitor element is positioned vertically between terminal portions. This spatial reorganization dramatically reduces the current path length and lead distance, thereby reducing ESL while maintaining terminal accessibility and structural integrity.
Solution Approach 2:
The capacitor element is nested within the terminal structure, with terminal portions extending from opposite sides to contact the capacitor element. This nested arrangement minimizes the distance between the capacitor element and terminals while maintaining a compact overall structure, effectively reducing lead distance and ESL.
2Volume of moving object
If the capacitor size is reduced for smaller footprint applications, then the device becomes more compact suitable for CPU chip applications, but the capacity and noise removability performance deteriorates
Solution Approach 1:
The patent utilizes vertical stacking and three-dimensional space utilization to maintain adequate capacitor capacity within a reduced footprint. By arranging terminal portions and capacitor element in a compact vertical configuration, the design achieves both small size and sufficient electrical performance for high-frequency applications.
Solution Approach 2:
The terminal portions are merged with the capacitor element assembly, with terminal portions extending directly from the capacitor element. This integration eliminates separate lead structures, reducing overall size while maintaining effective electrical connectivity and performance.
3Reliability
If conventional terminal structures are used with long leads, then the manufacturing process is simpler, but the ESR (equivalent series resistance) and ESL increase reducing high-frequency applicability
Solution Approach 1:
The patent employs a vertical three-dimensional terminal arrangement where terminal portions extend from opposite sides to contact the capacitor element. This spatial configuration reduces current path length and parasitic inductance, enabling high-frequency performance despite increased structural complexity compared to conventional linear leads.
Solution Approach 2:
The patent replaces conventional mechanical wire leads with a integrated terminal structure where terminal portions are formed as extensions of the capacitor element assembly. This substitution eliminates traditional lead wiring, reducing parasitic elements and improving high-frequency characteristics.
Data Source
AI summary
A solid electrolytic capacitor includes a capacitor unit having a cathode frame coupled to a cathode part of a capacitor element, and anode frames formed at the opposite sides of the capacitor unit sandwiching a cathode frame, and coupled to an anode part of the capacitor element. Flat parts provided at the opposite ends of anode terminals are coupled to the anode frames. A flat part provided in the center of a cathode terminal is coupled to the cathode frame. The capacitor unit is covered with coating resin. The solid electrolytic capacitor has a simplified structure and a lower ESL.