Capacitor Porous Base Insulating End Part Crack Prevention
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Solution Overview
Problem
Capacitors with high electrostatic capacitance face issues of brittle fracture during manufacturing and potential short circuits due to crack generation, especially when subjected to bending stress, and polarity limitations lead to unusability under reverse voltage.
Innovation Solution
A capacitor design featuring a conductive porous base material with a high-porosity part and a low-porosity part, where an insulating part covers or penetrates the end part of the high-porosity part, preventing crack generation and reducing the likelihood of short circuits by spacing the dielectric layer from the upper electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If layers are formed on the porous body to increase electrostatic capacitance, then higher electrostatic capacitance is achieved, but brittle fracture occurs when bending stress is produced
Solution Approach 1:
The capacitor is divided into multiple independent capacitor elements (first capacitor element and second capacitor element) that are arranged in parallel. Each capacitor element has its own porous body with electrode patterns formed thereon. This segmentation allows the structure to better withstand bending stresses while maintaining high electrostatic capacitance through the parallel arrangement.
Solution Approach 2:
Electrode patterns are selectively formed on specific regions (first region and second region) of the porous body surface, with insulating films formed in between. This local quality approach concentrates the capacitance-forming structures in specific areas, reducing overall mechanical stress while maintaining high capacitance in the active regions.
2Quantity of substance
If the dielectric layer is made thin to increase capacitance density, then higher electrostatic capacitance is achieved, but crack generation and breakdown become more likely
Solution Approach 1:
The invention uses a porous body as the base material for the capacitor elements. The porous structure provides a large surface area for capacitance formation, allowing for high capacitance density without requiring extremely thin dielectric layers. The porous structure also provides mechanical flexibility and stress distribution, reducing crack generation while maintaining high breakdown resistance.
3Ease of manufacture
If the capacitor structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but defect generation from crack formation increases
Solution Approach 1:
Multiple functional layers (porous body, insulating films, electrode patterns) are combined into an integrated capacitor element structure. The insulating films and electrode patterns are formed directly on the porous body in a sequential manufacturing process, merging the dielectric and electrode functions into a unified structure that is both manufacturable and reliable.
Data Source
AI summary
The present invention provides a capacitor including a conductive porous base material with a porous part, a dielectric layer and an upper electrode. The porous part, the dielectric layer, and the upper electrode are stacked on top of one another in this order to define a capacitance formation part. The capacitance format ion part is not present at a lateral end part of the porous part.