An electrolytic capacitor capable of operating at 75 g or greater is provided having a case with a base and a lid, with a wound capacitor element positioned on its side, lengthwise along the bottom of the base and with the underside of the lid pressed against the length of the capacitor element, to
An electrolytic capacitor capable of operating at 75 g or greater is provided having a case with a base and a lid, with a wound capacitor element positioned on its side, lengthwise along the bottom of the base and with the underside of the lid pressed against the length of the capacitor element, to frictionally engage the capacitor element. The case is provided with inwardly projecting surfaces, including a bulkhead at one end of the capacitor element and ridges on the lid, which function as barriers to restrict movement of the capacitor element within the case. A compartment is created at one end of the case, to allow space for terminals, which are embedded in a non-conductive support matrix.
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1. An electrolytic capacitor, comprising: (a) a case comprising (i) a base having an interior and an exterior, a bottom, a first side wall and a second side wall opposite the first side wall, a back wall and a front wall opposite the back wall, and (ii) a lid having a rim and an underside, wherein t
1. An electrolytic capacitor, comprising: (a) a case comprising (i) a base having an interior and an exterior, a bottom, a first side wall and a second side wall opposite the first side wall, a back wall and a front wall opposite the back wall, and (ii) a lid having a rim and an underside, wherein the lid overlays the interior of the base and is parallel to the bottom of the base, and wherein the rim of the lid is attached to the base to create a seal therewith;(b) a wound capacitor element, having an anode, a cathode and a dielectric layer, wherein the capacitor element is characterized by a width, a height, and a length, the capacitor element further having a first end and a second end opposite the first end, and a first tab and a second tab connected to the anode and cathode, respectively, whereby the capacitor element is positioned inside the case with the first end of the capacitor element facing the front wall of the base and the second end of the capacitor element facing the back wall of the base, and the underside of the lid and the bottom of the base are in contact with the capacitor element along its length with sufficient pressure to frictionally engage the capacitor element and resist the capacitor elements lengthwise movement relative to the case, and whereby a compartment is created within the case between the first end of the capacitor element and the front wall of the base, and the first and second tabs extend into the compartment;(c) a first terminal having a first end positioned in the compartment and connected to the first tab of the capacitor element and a second end extending through a first hole in the case;(d) a first hermetic seal attached to the exterior of the case and surrounding the first hole in the case, wherein the second end of the first terminal extends through the first hermetic seal and is electrically insulated from the case;(e) a second terminal having a first end positioned in the compartment and connected to the second tab of the capacitor element and a second end extending through a second hole in the case;(f) a second hermetic seal attached to the exterior of the case and surrounding the second hole in the case, wherein the second end of the second terminal extends through the second hermetic seal and is electrically insulated from the case; and(g) an electrolyte solution contained in the case and in contact with the capacitor element. 2. The capacitor of claim 1, wherein the capacitor can withstand 50 g, according to MIL-STD-202/Method 204, without failure. 3. The capacitor of claim 1, further comprising a bulkhead aligned parallel to the back wall and positioned between the back wall and the front wall, wherein the first end of the capacitor element is adjacent the bulkhead and the second end of the capacitor element is adjacent the back wall of the base, and wherein the bulkhead is a barrier to movement of the capacitor element towards the front wall of the base. 4. The capacitor of claim 3, wherein the bulkhead is integrally formed with the base, and the base further comprises a shelf extending between the bulkhead and the front wall of the base, and the first and second holes in the case are positioned in the shelf. 5. The capacitor of claim 3, wherein the bulkhead is integrally formed with the base, and wherein the base is formed by the process of stamping. 6. The capacitor of claim 1, wherein the capacitor element has an aspect ratio of width to height of from 1.5:1 to 7:1. 7. The capacitor of claim 6, wherein the interior of the base between the first side wall and the bottom and between the second side wall and the bottom has a radius of 0.125 inches or greater, through an angle of 75° or greater. 8. The capacitor of claim 1, wherein a pressure of 50 lbs./in2 or greater is applied to the lid when the capacitor is assembled, thereby compressing the capacitor element between the lid and the bottom of the base. 9. The capacitor of claim 8, wherein the interior of the base between the first side wall and the bottom and between the second side wall and the bottom conforms to the capacitor element. 10. The capacitor of claim 1, wherein the lid has an outer edge and the outer edge is recurved, to create at least two inward projections, such that the rim of the lid is facing away from the bottom of the base, and a portion of the underside of the lid in contact with the capacitor element is concave. 11. The capacitor of claim 1, wherein the anode and the cathode of the capacitor element comprise first and second wound foils, and the first and second tabs of the capacitor element are positioned + or −15% of the length of the foil from the midpoint of the respective first and second foils. 12. The capacitor of claim 1, wherein the first and second tabs are connected to the first and second terminals, respectively, and the tabs are bent less than 90°. 13. The capacitor of claim 1, further comprising a non-conductive matrix material positioned in the interior of the case and wherein the first and second terminals are embedded in the matrix material. 14. The capacitor of claim 13, wherein the rivets of the first and second terminal are aluminum, and the leads of the first and second terminals are tin plated copper. 15. An electrolytic capacitor, comprising: (a) a wound capacitor element, having an anode, a cathode and a dielectric layer, wherein the capacitor element is characterized by a width, a height, and a length, the capacitor element further having a first end and a second end opposite the first end, and a first tab and a second tab connected to the anode and cathode, respectively;(b) a case comprising (i) a base having an interior and an exterior, a bottom, a first side wall and a second side wall opposite the first side wall, a back wall and a front wall opposite the back wall, and a bulkhead aligned parallel to the back wall at a distance from the back wall approximately the length of the capacitor element, wherein the capacitor element is positioned in the base with the first end of the capacitor element adjacent the bulkhead and the second end of the capacitor element adjacent the back wall, wherein the bulkhead is a barrier to movement of the capacitor element towards the front wall of the base, and wherein the first and second tabs extend into a compartment formed between the front wall of the base and first end of the capacitor element; and (ii) a lid having a rim and an underside, wherein the lid overlays the interior of the base and the capacitor element, and wherein the rim of the lid is attached to the base to create a seal therewith, and wherein the underside of the lid is in contact with the capacitor element along the length of the capacitor element;(c) an electrolyte solution contained in the case and in contact with the capacitor element;(d) a first terminal positioned in a first hole in the base of the case, the first terminal having (i) a rivet positioned within the interior of the case and connected to the first tab of the capacitor element, and (ii) a lead extending outside of the case, wherein the rivet and the lead of the first terminal are bonded together [welded] and comprise different metallic compositions;(e) a first hermetic seal attached to the exterior of the case and surrounding the first hole in the base, wherein the lead of the first terminal extends through the first hermetic seal and is bonded thereto;(f) a second terminal positioned in a second hole in the base of the case, the second terminal having (i) a rivet positioned within the interior of the case and connected to the first tab of the capacitor element, and (ii) a lead extending outside of the case, wherein the rivet and the lead of the second terminal are bonded together [welded] and comprise different metallic compositions; and(g) a second hermetic seal attached to the exterior of the case and surrounding the second hole in the base, wherein the lead of the second terminal extends through the second hermetic seal and is bonded thereto. 16. The capacitor of claim 15, wherein the capacitor can withstand 75 g, according to MIL-STD-202/Method 204, without failure. 17. The capacitor of claim 16, wherein the bulkhead is integrally formed with the base, and the base further comprises a shelf extending between the bulkhead and the front wall of the base, and the first and second holes in the case are positioned in the shelf. 18. The capacitor of claim 16, wherein the bulkhead is integrally formed with the base, and wherein the base is formed by the process of stamping. 19. The capacitor of claim 15, wherein the capacitor element has an aspect ratio of width to height of from 1.5:1 to 4:1. 20. The capacitor of claim 15, wherein the interior of the base between the first side wall and the bottom and between the second side wall and the bottom has a radius of 0.125 inches or greater, through an angle of 75° or greater. 21. The capacitor of claim 15, wherein a pressure of 75 lbs./in2 or greater is applied to the lid when the capacitor is assembled, thereby compressing the capacitor element between the lid and the bottom of the base. 22. The capacitor of claim 21, wherein the interior of the base between the first side wall and the bottom and between the second side wall and the bottom conforms to the capacitor element. 23. The capacitor of claim 15, wherein the lid has an outer edge and the outer edge is recurved, such that the rim of the lid is facing away from the bottom of the base, and at least two inward projections in the shape of ridges engage the capacitor element. 24. The capacitor of claim 15, wherein the anode and the cathode of the capacitor element comprise first and second wound foils, and the first and second tabs of the capacitor element are positioned + or −10% of the length of the foil from the midpoint of the respective first and second foils. 25. The capacitor of claim 15, wherein the bulkhead extends upward from the bottom of the base to a height of from ⅓ or more of the height of the capacitor element. 26. The capacitor of claim 25, wherein the first and second tabs extend from the first end of the capacitor element at ½ the height of the capacitor element or greater, as measured from the bottom of the base. 27. The capacitor of claim 15, wherein the cathode of the capacitor element extends 0.080 inches or greater beyond the anode at the first end and the second end of the capacitor element. 28. The capacitor of claim 15, further comprising a non-conductive matrix material positioned in the interior of the case and wherein the first and second terminals are embedded in the matrix material. 29. The capacitor of claim 28, further comprising a shelf extending between the bulkhead and the front wall of the base, and the first and second holes in the case are positioned in the shelf, and wherein the matrix material is a unitary part and is positioned on the shelf, and the matrix material restricts movement of the first and second terminals relative to the case. 30. The capacitor of claim 15, wherein the base comprises a first inward projection capable of resisting movement of the capacitor element relative to the case and the lid comprises a second inward projection capable of resisting movement of the capacitor element relative to the case, and wherein the first and second inward projections are perpendicular to each other.
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