Asymmetric Shield Electrodes for High Voltage MLCCs
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Solution Overview
Problem
High voltage multi-layered ceramic capacitors (MLCCs) are susceptible to arcing in air, which limits their voltage rating and can cause electrical breakdown, and existing solutions like coatings are expensive and prone to mechanical damage.
Innovation Solution
The design incorporates asymmetrical shield electrodes and a serial configuration with multiple capacitors in series, allowing for higher voltage operation without arcing failures, achieved through alternating parallel layers with dielectric in between and shield layers with distinct projections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high voltage is applied to MLCC in air, then voltage rating is improved, but surface arcing occurs causing electrical breakdown
Solution Approach 1:
A shield electrode is introduced as an intermediary element between the active electrodes. This shield electrode has a projection that extends beyond the active electrode projection, creating a protective barrier that prevents surface arcing along the capacitor surface while maintaining the high voltage capability between active electrodes
2Reliability
If coatings are applied to prevent arcing, then reliability is improved, but cost increases and mechanical damage risk increases
Solution Approach 1:
The capacitor structure itself provides arcing prevention through the asymmetric shield electrode design. The shield electrode's extended projection creates a geometric barrier that prevents surface arcing without requiring external coatings or additional processing steps, making the system self-protecting
3Reliability
If shield electrodes are added to MLCC, then arcing resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The shield electrode is designed with asymmetric geometry where its projection extends beyond the active electrode projection in at least one direction. This asymmetric design provides effective arcing prevention while maintaining compatibility with standard manufacturing processes for multilayer ceramic capacitors
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 design enables reliable high voltage operation up to 2500V without arcing failures in air, maintaining high capacitance and voltage breakdown performance, eliminating the need for additional coatings and enhancing manufacturing flexibility.
Implementation Method 1
a first active electrode and a first floating electrode in a first common plane, and a second active electrode and a second floating electrode in a second common plane, wherein at least one shield layer is adjacent to an outermost first layer of the first layers
Implementation Method 2
The tendency for surface arcing in air has been exploited to dissipate energy to ground... However, in electronic components, such as capacitors, if arcing occurs it can cause electrical breakdown
Data Source
AI summary
An improved multi-layered ceramic capacitor, and method of making the multi-layered ceramic capacitor, is described. The capacitor has an active area comprising first layers and second layers in alternating parallel arrangement with dielectric there between. The first layer comprises a first active electrode and a first floating electrode in a common plane and the second layer comprises a second active electrode and a second floating electrode in a second common plane. At least one shield layer is adjacent to an outermost first layer of the first layers wherein the shield layer has a first projection and the first layers have a second projection wherein the first projection and the second projection are different.