Solid electrolytic capacitor and method for manufacturing the same

Abstract

A portion of an anode lead frame 3 of a solid electrolytic capacitor 1 is bent to form a protruding portion 4 that protrudes toward an anode lead 20. The protruding portion 4 includes a first horizontal portion 41 positioned higher than and substantially parallel to the anode lead 20, a second horizontal portion 40 contacting the anode lead 20, a sloping portion 42 linking the inner end of the first horizontal portion 41 with the outer end of the second horizontal portion 40, and an auxiliary bent portion 43 bent upward from the inner end of the second horizontal portion 40 and substantially symmetrical with the sloping portion 42. A contact surface 46 of the second horizontal portion 40 with the anode lead 20 is formed flat, and a surface 47 of the second horizontal portion 40 on the opposite side to the contact surface 46 is formed with a rounded curvature.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front sectional view of a solid electrolytic capacitor,

FIG. 2 is an enlarged view of the leading end of an anode lead frame,

FIGS. 3A and 3B are illustrative diagrams showing the effects of a protruding portion in the present embodiment, while FIG. 3C shows an alternative protruding portion,

FIG. 4 is a plan view of a metal plate that is to form lead frames,

FIG. 5 is a perspective view showing the step of forming a lead frame,

FIG. 6 is a cross-sectional view showing the step of forming a lead frame,

FIG. 7 is a perspective view showing the step of forming a solid electrolytic capacitor,

FIG. 8 is a front sectional view of a conventional solid electrolytic capacitor,

FIG. 9 shows a manufacturing step for a conventional electrolytic capacitor,

FIG. 10 is a cross-sectional view of a conventional capacitor element,

FIG. 11 is a front view showing a conventional lead frame,

FIG. 12 shows a conventional capacitor element attached at an angle, and

FIG. 13 shows a conventional capacitor element attached at an angle.

Claims

1. A solid electrolytic capacitor comprising: a capacitor element with a protruding anode lead;an anode lead frame connected to the anode lead; anda cathode lead frame attached to a peripheral surface of the capacitor element, wherein the capacitor element, a portion of the anode lead frame, and a portion of the cathode lead frame are covered by a housing,wherein the anode lead frame has a protruding portion that protrudes within the housing toward the anode lead,the protruding portion includes a first horizontal portion positioned higher than and substantially parallel to the anode lead, a second horizontal portion contacting the anode lead, a linking portion linking the first and second horizontal portions, and an auxiliary bent portion bent upward from an inner end of the second horizontal portion and substantially symmetrical with the linking portion, anda contact surface of the second horizontal portion with the anode lead is flat, and a surface of the second horizontal portion on an opposite side to the contact surface has a rounded curvature.

2. The solid electrolytic capacitor according to claim 1, wherein the contact surface of the second horizontal portion with the anode lead is formed by a pressing process for flattening the protruding portion.

3. The solid electrolytic capacitor according to claim 1, wherein the first horizontal portion is positioned at substantially the same height from the anode lead as the cathode lead frame contacting the peripheral surface of the capacitor element.

4. A manufacturing method for the solid electrolytic capacitor as claimed in claim 1, comprising the steps of: forming a protruding portion by performing a bending process or a deep drawing process on a portion of an anode lead frame; andapplying a pressing force to and flattening a contact surface with an anode lead by further performing a pressing process on a second horizontal portion of the protruding portion, and forming a rounded curvature on a surface of the second horizontal portion on an opposite side to the contact surface.