Capacitor Assemblies With Fusing Wire Bonds for High-Power Modules
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Solution Overview
Problem
Ceramic capacitors are unreliable in high-power, rapid discharge applications due to dielectric breakdown, leading to catastrophic failure and potential damage to other electrical components, limiting their use in applications requiring high energy storage and reliability.
Innovation Solution
A capacitor assembly with a wire bond that breaks connection when an electrical current reaches a fusing current, preventing catastrophic failure, and an energy storage module comprising multiple capacitor assemblies connected in series or parallel with a main conductor, allowing for controlled energy discharge and high energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ceramic capacitors are used for high energy storage, then energy density is improved, but reliability deteriorates due to dielectric breakdown and catastrophic failure
Solution Approach 1:
The patent divides a single large-capacity ceramic capacitor into multiple smaller-capacity ceramic capacitors connected in parallel within a capacitor assembly. This segmentation reduces the energy storage capacity of individual ceramic capacitors, thereby reducing the probability of dielectric breakdown in each unit, while the overall assembly maintains high energy storage capacity through the combined capacity of multiple units.
Solution Approach 2:
The patent introduces a polymer capacitor as an intermediary component in the capacitor assembly, connected in parallel with the ceramic capacitors. The polymer capacitor serves as a protective mediator that can absorb fault currents and prevent catastrophic failure of the entire assembly when a ceramic capacitor fails, thereby improving reliability while maintaining energy storage capacity.
2Speed
If ceramic capacitors are used for rapid discharge applications, then discharge speed is improved, but reliability deteriorates due to catastrophic failure
Solution Approach 1:
The patent segments the rapid discharge function across multiple ceramic capacitors connected in parallel, each operating at reduced stress levels. This segmentation allows the system to maintain high discharge speed capability while reducing the likelihood of any single capacitor experiencing dielectric breakdown under rapid discharge conditions.
Solution Approach 2:
The polymer capacitor acts as an intermediary protective element that can handle fault currents during rapid discharge operations. When a ceramic capacitor fails during rapid discharge, the polymer capacitor absorbs the fault current and prevents catastrophic failure, allowing the system to maintain reliability while preserving the rapid discharge capability of the ceramic capacitors.
3Power
If a single capacitor fails in a high-power application, then catastrophic failure occurs, but system continuity is lost
Solution Approach 1:
The patent segments the high-power capability across multiple ceramic capacitors connected in parallel within a single capacitor assembly. This segmentation ensures that the failure of one capacitor does not result in the failure of the entire assembly, as the remaining capacitors can continue to provide high-power capability, thereby maintaining system continuity.
Solution Approach 2:
The polymer capacitor serves as an intermediary protective component that maintains system continuity during capacitor failures. When a ceramic capacitor fails in a high-power application, the polymer capacitor absorbs the fault current and prevents catastrophic failure of the entire assembly, ensuring that the system can continue operating with reduced but still functional power capability.
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
The solution prevents catastrophic failure of the capacitor assembly by creating an open circuit when a single capacitor fails, maintaining the functionality of the energy storage module and ensuring reliable high-energy discharge, even in high-power applications.
Implementation Method 1
The wire bond is configured to break connection with an electrical circuit when an electrical current through the wire bond reaches a fusing current
Data Source
AI summary
A capacitor assembly includes a capacitor having ends. A terminal covers less than an area of one end. A wire bond has opposing ends with one end being coupled to the terminal and is configured to break connection with a circuit when an electrical current through the wire bond reaches a fusing current. An energy storage module includes at least two capacitor assemblies. The wire bond of one capacitor is electrically connected to the second terminal of an adjacent capacitor. An energy storage assembly includes two energy storage modules stacked one on top of the other. A pulse forming network includes conductors and at least two energy storage modules. A method of making a module includes charging each of the capacitors, removing each capacitor that fails, connecting one end of a wire bond to one terminal and connecting the other end to an adjacent capacitor or to a conductor.