Vertical Capacitor Clamping Assembly for Lead Stress Protection
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Solution Overview
Problem
The challenge lies in effectively mounting high-power capacitors on circuit boards, particularly radial-lead capacitors, which face issues with lead weakening or fracture due to weight, vibration, and heat when mounted vertically without support, limiting capacitive storage in space-restricted applications.
Innovation Solution
A capacitor assembly with axial-lead capacitor elements retained longitudinally perpendicular to the mounting surface using a clamping assembly comprising upper and lower electrically insulating sections forming a cylinder with internal recesses, and a conductive path for electrical connection, which includes pins to mitigate torsional and vibrational stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If axial-lead capacitors are mounted vertically perpendicular to the board without support structure, then board surface area is reduced and capacitive storage density is increased, but lead fracture risk increases due to weight, vibration, and heat
Solution Approach 1:
A support structure comprising a support member extending from the board surface and a clamp member is introduced as an intermediary between the capacitor leads and the board. This mediator provides mechanical support to the vertically mounted capacitors, distributing the stress from weight, vibration, and heat away from the fragile leads while maintaining the vertical orientation that saves board space.
Solution Approach 2:
The support structure utilizes the vertical dimension by extending a support member from the board surface upward, allowing capacitors to be mounted perpendicular to the board. This dimensional approach enables space-efficient vertical mounting while the support structure provides the necessary mechanical reinforcement that would be unavailable in traditional planar mounting configurations.
2Adaptability or versatility
If radial-lead capacitors are used with complex internal geometry, then vertical mounting is possible, but adaptability to axial-lead design is limited
Solution Approach 1:
The support structure with its support member and clamp member is designed as a universal mounting mechanism that can accommodate different capacitor types and configurations. The clamp member can adjust to secure various capacitor geometries, making the support structure adaptable to both axial-lead and radial-lead capacitors, as well as different capacitor sizes and shapes, without requiring redesign of the mounting system.
3Quantity of substance
If high power density capacitors are mounted vertically, then capacitive storage is maximized, but operational torsion and heat cause damage to connections and board
Solution Approach 1:
The support structure provides preemptive protection against thermal and mechanical damage by positioning the support member and clamp member to bear the stresses of operational torsion and heat before they can reach the capacitor leads and board connections. This prior cushioning prevents damage accumulation during operation, allowing high power density capacitors to function reliably in space-constrained applications.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
A capacitor assembly (110;210;310;410) comprises a plurality of capacitor elements (112;212;312;412), a clamping assembly (114;214;314;414), and a conductive path (116;216;316;416). The clamping assembly (114;214;314;414) retains the plurality of capacitor elements (112;212;312;412) longitudinally perpendicular to an adjacent mounting surface (122;222;322;422). The conductive path (116;216;316;416) electrically connects the plurality of capacitor elements (112;212;312;412) to one or more circuit elements disposed proximate the adjacent mounting surface (122;222;322;422).