Winding Capacitor Package With Layered Moisture Barrier
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Solution Overview
Problem
Current winding capacitor packages lack effective protection and structural enhancements to prevent moisture ingress and ensure reliable performance in various applications, leading to potential rusting and reduced reliability.
Innovation Solution
A winding capacitor package structure that includes a winding assembly, a package assembly with a casing structure and a filling body of layered materials, and a conductive assembly with pins, where the filling body is retained by a retaining body within the casing structure, and optionally includes moisture barrier layers to prevent external moisture from reaching the winding assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple package structure is used, then manufacturing is easier, but moisture protection and reliability are insufficient
Solution Approach 1:
The package structure is divided into multiple functional layers including a filling body layer, a moisture barrier layer, and a sealing structure. The filling body is segmented into multiple portions that can be independently positioned and secured, allowing each segment to perform its specific function optimally while collectively providing comprehensive moisture protection.
Solution Approach 2:
The package employs composite material construction by combining different materials with complementary properties: the filling body uses insulating and protective materials, the moisture barrier layer uses materials with low moisture permeability, and the sealing structure uses materials that provide both mechanical strength and environmental sealing. This composite approach enhances overall reliability without requiring a single complex component.
2Reliability
If the filling body is loosely positioned, then assembly is simpler, but protection against moisture ingress is reduced
Solution Approach 1:
The moisture barrier layer is pre-formed and integrated with the filling body before final assembly. The sealing structures are pre-positioned on the package casing, and the conductive pins are pre-coated with protective materials. These preliminary actions ensure that when components are assembled, the moisture protection and sealing functions are already in place, maintaining both reliability and manufacturing efficiency.
Solution Approach 2:
The moisture barrier layer is nested within or integrated with the filling body structure. The sealing structures are nested within the package casing, and the conductive pins are nested within the filling body with their exposed portions extending through designated openings. This nested arrangement ensures tight integration and effective sealing while simplifying the assembly process through hierarchical positioning.
3Reliability
If conductive pins are exposed without sealing, then electrical connection is easier, but rusting and reliability issues occur
Solution Approach 1:
The conductive pins are coated with a thin protective film or flexible sealing material that conforms to the pin surface. This thin film provides corrosion protection while maintaining electrical conductivity and allowing the pins to be inserted and connected without complex sealing mechanisms. The flexible nature of the coating accommodates manufacturing tolerances and assembly variations.
Solution Approach 2:
A protective coating or sealing material acts as an intermediary between the conductive pins and the external environment. This intermediary layer provides the necessary corrosion protection while allowing the pins to perform their electrical connection function. The intermediary material is selected to be electrically conductive or to maintain contact pressure for reliable electrical connection while blocking moisture and corrosive elements.
Data Source
AI summary
A winding capacitor package structure and a method of manufactured the same are provided. The winding capacitor package structure includes a winding assembly, a package assembly, a conductive assembly, and a bottom carrier frame. The winding assembly includes a winding positive foil and a winding negative foil. The winding assembly is enclosed by the package assembly. The package assembly includes a casing structure and a filling body received inside the casing structure. The casing structure includes a main casing for enclosing the filling body and a retaining body inwardly bent from a bottom side of the main casing. The filling body includes a plurality of layered structures, and each of the layered structure is connected between the winding assembly and the casing structure. Therefore, the filling body including the layered structures can be retained and limited inside the casing structure through the retaining body.