Capacitive Storage Element Titanate Layer Uniformity
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Solution Overview
Problem
The existing methods for manufacturing capacitive storage elements with porous substrates face challenges in achieving adequate dielectric strength due to uneven titanate layer deposition, where protruding parts of the substrate are inadequately covered, affecting the minimal local thickness and layered nature of the titanate layer, which is critical for high-voltage applications like electric vehicle energy storage units.
Innovation Solution
Applying an external electrical field to concentrate titanate particles on the protruding areas of a porous substrate, followed by heating to create a stable titanate layer with a uniform thickness of 0.2 μm to 2.0 μm, ensuring adequate dielectric strength and energy density for capacitive storage elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a porous substrate is used as a mold for manufacturing capacitive storage elements, then the substrate provides structural support and porosity for layer deposition, but the protruding parts of the porous substrate remain uncovered or inadequately covered by the titanate layer, resulting in non-uniform layer thickness and reduced dielectric strength
Solution Approach 1:
The substrate surface is pre-treated with a surface treatment layer (such as a primer or adhesion-promoting layer) before depositing the titanate dielectric layer. This preliminary action modifies the surface properties of protruding areas to enhance titanate deposition and adhesion, ensuring uniform coverage and thickness across the entire substrate surface including protruding parts.
Solution Approach 2:
An intermediate surface treatment layer is introduced between the porous substrate and the titanate dielectric layer. This intermediary layer acts as a mediator that facilitates uniform titanate deposition by modifying surface energy, wettability, or chemical reactivity, thereby ensuring adequate coverage on protruding substrate parts and achieving uniform layer thickness.
2Reliability
If the titanate layer thickness is increased to ensure adequate dielectric strength for high-voltage applications, then the dielectric strength improves, but the energy density decreases due to the increased distance between electrodes
Solution Approach 1:
The titanate dielectric layer is deposited with locally optimized thickness and properties. By ensuring uniform coverage on protruding substrate parts through surface treatment, the layer achieves adequate minimum thickness in all areas while maintaining overall thinness. This local quality control allows the dielectric layer to provide sufficient breakdown strength without excessive overall thickness, thereby preserving energy density.
Solution Approach 2:
The physical and chemical parameters of the titanate layer are optimized, including its composition, crystalline structure, and density. By controlling deposition conditions and performing post-deposition treatments, the layer achieves high dielectric strength with minimal thickness, thus resolving the contradiction between reliability and energy density.
3Manufacturing precision
If conventional deposition methods are used without an external electrical field, then the deposition process is simpler, but the titanate particles are not concentrated in the protruding places, resulting in non-uniform layer distribution and inadequate dielectric strength
Solution Approach 1:
The conventional mechanical or chemical deposition process is replaced or supplemented by an electrical field-assisted deposition method. The external electrical field exerts electrostatic forces on the titanate particles during deposition, directing them preferentially to protruding areas of the substrate. This substitution of mechanical/chemical mechanisms with electrical field control achieves uniform layer distribution while maintaining process feasibility.
Solution Approach 2:
The deposition process parameters are changed by introducing an external electrical field with controlled strength and configuration. This parameter change modifies the particle transport and deposition mechanisms, causing titanate particles to concentrate in protruding areas and form a uniform layer distribution without requiring complex multi-step processes.
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 method ensures a uniform titanate layer distribution, enhancing dielectric strength and energy density, making capacitive storage elements suitable for electric and hybrid vehicle drives with improved performance and reduced costs compared to lithium-ion batteries.
Implementation Method 1
an external electrical field is applied in the direction of the layer sequence to form a closed titanate layer having an adjustable minimal layer thickness
Implementation Method 2
when the field is applied, a fluid containing titanate particles is applied to the substrate. The titanate particles are concentrated in the protruding places (or in the protruding areas) of the porous substrate, since a higher field line density of the electrical field results there
Implementation Method 3
followed by heating to create a stable titanate layer with a uniform thickness of 0.2 μm to 2.0 μm
Implementation Method 4
heating to create a stable titanate layer
Data Source
AI summary
A method for manufacturing a capacitive storage element having a layer system on one side of a porous substrate, which is designed as a conductive substrate or has a conductive surface layer at least on the one side, the layer system having a layer sequence of a dielectric titanate layer and an electrically conductive layer. It is provided that to form a closed titanate layer having an adjustable minimum layer thickness, an external electrical field is applied in the direction of the layer sequence, and when the field is applied, a fluid containing titanate particles is applied to the substrate. A corresponding capacitive storage element and the use of a capacitive storage element as a storage element of an electrical energy storage unit for supplying energy to an electric drive or hybrid drive of a motor vehicle are also described.