Thin and Thick Wire Lead Assembly for Electrolytic Capacitor
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Solution Overview
Problem
Conventional solid electrolytic capacitors face challenges in achieving a balance between increased contact points between the anode body and anode lead, which reduces equivalent series resistance (ESR), while minimizing the negative effects of increased internal resistance in the lead, thereby limiting their electrical capabilities.
Innovation Solution
A solid electrolytic capacitor design featuring a sintered porous anode body with a first anode lead embedded within and a second anode lead extending externally, where the first lead has a larger diameter to increase contact points and the second lead has a smaller diameter to reduce internal resistance, connected via a method that minimizes energy consumption during welding and simplifies processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single thick anode lead is used to increase contact points, then ESR decreases, but the welding energy consumption and processing complexity increase
Solution Approach 1:
The anode lead assembly is segmented into two parts with different diameters, allowing the external second anode lead to have smaller size that requires less welding energy to attach to terminations, while the embedded first anode lead maintains larger diameter for low ESR contact with the anode body.
Solution Approach 2:
The diameter parameter of the anode lead is changed along its length, with the embedded portion having larger diameter for electrical contact and the external portion having smaller diameter for easier welding and processing, thus reducing overall welding energy consumption.
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 results in ultralow ESR levels and improved electrical capabilities, with reduced material costs and processing complexity, while maintaining stability and ease of manipulation during chemical processes.
Implementation Method 1
The anode can be formed by first pressing a tantalum powder into a pellet that is then sintered to create fused connections between individual powder particles
Implementation Method 2
A first portion of the first anode lead is embedded within the porous anode body
Implementation Method 3
welding the second anode lead to an anode termination to form an electrical connection between the second anode lead and the anode termination
Data Source
AI summary
A capacitor containing a solid electrolytic capacitor element including a sintered porous anode body, a first anode lead, and a second anode lead is provided. The first anode lead has a thickness that is larger than a thickness of the second anode lead. A portion of the first anode lead is embedded in the porous anode body, and a second portion of the first anode lead extends from a surface thereof in a longitudinal direction. Meanwhile, the second anode lead is electrically connected to the anode body for connection to an anode termination. In one embodiment, the second anode lead can be directly connected to a surface of the anode body. In another embodiment, the second anode lead can be indirectly connected to the anode body such as via attachment at an end of the second portion of the first anode lead.