Capacitor Pore Filling Insulation for Leakage Suppression
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Solution Overview
Problem
Capacitors with porous metal base materials face mechanical strength issues due to thin dielectric and upper electrode layers, leading to potential cracks and peeling, which can cause leakage currents.
Innovation Solution
Incorporating an insulating material into the pores of the conductive porous base material to prevent electron migration and leakage currents, even when cracks or peeling occur in the dielectric and upper electrode layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a dielectric layer and upper electrode layer are formed in pores of a porous metal base material to increase electrostatic capacitance, then the electrostatic capacitance increases, but the mechanical strength of the layers is lowered and cracks or peeling may occur
Solution Approach 1:
The patent applies composite materials by combining the porous metal base material with a resin layer that has adhesive properties. The resin layer acts as a composite component that integrates with both the metal base material and the dielectric/upper electrode layers, creating a multi-material structure that simultaneously provides mechanical strength and electrical functionality.
Solution Approach 2:
The resin layer is formed beforehand to cover the porous metal base material before the dielectric layer and upper electrode layer are formed. This pre-formed resin layer serves as a cushioning support that prevents cracks and peeling from occurring in the subsequent thin layers, addressing the mechanical strength issue before the capacitance-forming layers are created.
2Quantity of substance
If the dielectric layer and upper electrode layer are made very thin to form in small pores, then the surface area per volume increases and electrostatic capacitance increases, but leakage current occurs when cracks or peeling expose the metal base material
Solution Approach 1:
The resin layer serves as an intermediary substance between the porous metal base material and the dielectric/upper electrode layers. When cracks or peeling occur and expose the metal base material, the resin layer acts as an intermediate barrier that prevents direct contact between the metal and the external environment, thereby suppressing leakage current while allowing the thin capacitance-forming layers to maintain high electrostatic capacitance.
3Area of stationary object
If thin dielectric and upper electrode layers are formed to achieve high electrostatic capacitance, then the area of capacitance-forming part increases, but the mechanical strength is lowered making the structure more fragile
Solution Approach 1:
The resin layer provides localized mechanical support specifically at the regions where the thin dielectric and upper electrode layers are formed in the pores. This local reinforcement allows the capacitance-forming layers to maintain their thin structure for high surface area while the resin provides the necessary mechanical strength at critical locations where cracks and peeling are most likely to occur.
Data Source
AI summary
A capacitor including a conductive porous base material having a plurality of pores, a dielectric layer on the conductive porous base material, an upper electrode on the dielectric layer, and an insulating material that extends into the plurality of pores.