Capacitor Conductive Base Material Sintering
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Solution Overview
Problem
Existing capacitor technologies face challenges in achieving both high electrostatic capacitance and strength, as simple sintering of metal powders often results in insufficient capacitance due to pore crushing, and bonding issues between the metal support and sintered body, particularly at high temperatures.
Innovation Solution
The use of a combination of metal powders with different average grain diameters and melting points, along with a metal support, allows for the formation of a conductive base material with high specific surface area, enabling both high electrostatic capacitance and strength without a metal support, and effective bonding through surface roughening or low melting-point metal layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal powders are sintered at high temperature to advance sintering and obtain sufficient strength, then strength is improved, but pores of the metal sintered body crush to make sufficient electrostatic capacitance difficult to be obtained
Solution Approach 1:
The invention changes the sintering temperature parameter to a moderate range (800°C to 1000°C) that balances pore preservation and strength requirements. Additionally, it introduces a specific porosity parameter (30% or more) as a control criterion to ensure sufficient electrostatic capacitance while maintaining adequate strength through optimized sintering conditions.
2Reliability
If metal powders are sintered at low temperature to maintain pores and obtain high electrostatic capacitance, then electrostatic capacitance is improved, but sufficient strength cannot be secured
Solution Approach 1:
The invention establishes a minimum sintering temperature of 800°C to ensure sufficient strength while preventing excessive pore collapse. This temperature parameter optimization allows the metal sintered body to achieve both adequate mechanical strength and sufficient porosity for high electrostatic capacitance.
3Strength
If firing is performed at high temperature to bond the metal support and the metal sintered body, then bonding strength is improved, but pores of the conductive base material with high specific surface area crush to make sufficient electrostatic capacitance difficult to be obtained
Solution Approach 1:
The invention optimizes the firing temperature to the same moderate range (800°C to 1000°C) that balances bonding strength and pore preservation. This parameter optimization ensures sufficient bonding between the metal support and sintered body while maintaining the porosity necessary for high electrostatic capacitance.
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 approach enables the creation of capacitors with enhanced electrostatic capacitance density and mechanical strength, while reducing the risk of warping and improving bonding between the metal support and sintered body, thus overcoming previous limitations.
Implementation Method 1
simple sintering of metal powders
Implementation Method 2
a dielectric layer covering at least the porous portion
Data Source
AI summary
A capacitor that includes a conductive base material with high specific surface area, a dielectric layer covering the conductive base material with high specific surface area, and an upper electrode covering the dielectric layer, in which the conductive base material with high specific surface area is formed of a metal sintered body as a whole.