Capacitor Electrode Structure for Low ESR and High Withstand Voltage
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Solution Overview
Problem
Existing capacitors face challenges in achieving high withstand voltage and low ESR (Equivalent Series Resistance) due to difficulties in manufacturing internal electrode parts that are both thin and thick enough to ensure stable performance and cost-effectiveness, particularly when using heavy edge structures.
Innovation Solution
A capacitor design that includes a heavy edge portion connected to external electrodes, supported by an edge support layer made of a different metal, allowing simultaneous formation with internal electrode parts without disrupting the manufacturing process, and using vapor deposition or coating methods to achieve the desired thickness and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the internal electrode parts are made thinner to increase withstand voltage, then the surface resistivity is raised, but the connection resistance of the connecting parts becomes high
Solution Approach 1:
The electrode structure is segmented into two functional parts: thin internal electrode parts for high withstand voltage and thick heavy edge portions for low connection resistance. This segmentation allows each part to be optimized independently for its specific function, resolving the contradiction between withstand voltage and connection resistance.
Solution Approach 2:
Different thicknesses are applied to different locations of the electrode structure. The internal electrode parts are made thin to increase surface resistivity and withstand voltage, while the heavy edge portions at the connecting parts are made thick to reduce connection resistance. This local differentiation of quality resolves the contradiction by applying appropriate thickness to each location based on its functional requirements.
2Object-affected harmful factors
If only the edge parts are made thicker to reduce connection resistance, then the difference in thickness from the internal electrode parts becomes too large, but manufacturing stability and cost-effectiveness deteriorate
Solution Approach 1:
The heavy edge portions are formed simultaneously with the internal electrode parts in the same manufacturing process, preparing the thickness differentiation in advance. This preliminary action allows the thickness difference to be built into the structure during a single process run, avoiding the need for separate thickening operations and maintaining manufacturing stability and cost-effectiveness.
Solution Approach 2:
The thickness parameter of the electrode structure is varied by location during the manufacturing process. By controlling deposition parameters or material application parameters, the system produces different thicknesses (thin internal electrodes vs. thick heavy edge portions) in a single process, maintaining ease of manufacture while achieving the desired resistance characteristics.
3Object-affected harmful factors
If the heavy edge portion is made several times thicker than the internal electrode part to reduce ESR, then the manufacturing process complexity increases
Solution Approach 1:
The same manufacturing process is used to form both the thin internal electrode parts and the thick heavy edge portions, making the process universal. By using a single deposition or coating process that can accommodate variable thickness requirements, the system reduces manufacturing process complexity while still achieving the ESR reduction benefits of thick heavy edge portions.
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 capacitors with improved connection performance, reduced ESR, and cost-effective production by ensuring precise thickness and integration of the edge support layer, maintaining mechanical and electrical stability.
Implementation Method 1
an edge support layer with a metal layer laminated (stacked) on at least one of the top and bottom of the heavy edge portion
Implementation Method 2
The electrode layer may be a vapor deposition layer (a layer produced by vapor deposition) of the first metal on the dielectric layer and the edge support layer may be a vapor deposition layer (a layer produced by vapor deposition) of the second metal on the heavy edge portion
Data Source
AI summary
A capacitor (1) includes a main body (10) in which a dielectric layer (13) and an electrode layer (11) are laminated, and an external electrode (20) connected to at least a part of the main body. The electrode layer (11) includes a heavy edge portion (16) with a connecting part (18), which connects to the external electrode and is thicker than an internal electrode part (15). The capacitor (1) further includes an edge support layer (12) that is made of metal and is laminated on the heavy edge portion (16).