EV Film Capacitor Electrode Structure for Surface Arc-Over Shielding
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Solution Overview
Problem
Conventional film capacitors for electric vehicles face insulation destruction due to surface arc-over caused by strong electric fields, which narrows the distance between external connection electrode layers, leading to breakdown voltage issues in EV power conversion devices.
Innovation Solution
A capacitor design with a high withstand voltage electrode structure, featuring a winding body with inner, intermediate, and outer windings, and metal electrode layers, where arc shield metal patterns on the intermediate winding connect to external electrode layers to prevent insulation destruction and uniformize the electric field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the distance between external connection electrode layers is reduced to improve compactness, then the capacitor size is reduced, but surface arc-over occurs due to strong electric field causing insulation destruction
Solution Approach 1:
An arc shield pattern film is introduced as an intermediary component between the external connection electrode layers. This film includes a metal pattern that acts as a shield to prevent direct arc-over between the electrode layers, allowing the distance between them to be reduced while maintaining insulation integrity through the protective intermediary layer.
Solution Approach 2:
The arc shield pattern film is implemented as a thin film structure with metal patterns deposited on it. This thin film approach provides effective arc shielding while occupying minimal space, enabling compact capacitor design without compromising the insulation between electrode layers.
2Reliability
If arc shield pattern film is added to prevent surface arc-over, then insulation integrity is improved, but device complexity increases
Solution Approach 1:
The arc shield pattern is merged with the dielectric film structure by depositing a metal pattern directly on the dielectric film surface. This integration combines the shielding function with the existing dielectric layer, avoiding the need for a completely separate shielding component and thereby reducing overall structural complexity.
Solution Approach 2:
The dielectric film serves multiple functions: it provides electrical insulation between electrodes and simultaneously serves as the substrate for the arc shield metal pattern. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure while maintaining insulation integrity.
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 design effectively shields surface arc-over phenomena, improving breakdown voltage and preventing insulation destruction, thus enhancing the reliability of EV power conversion devices.
Implementation Method 1
arc shield metal patterns on the intermediate winding connect to external electrode layers to prevent insulation destruction
Implementation Method 2
an electric field is uniformized, thereby improving a breakdown voltage
Data Source
AI summary
Provided is a capacitor having a high withstand voltage electrode structure, for an electric vehicle (EV), the capacitor including a winding body wound as an inner winding, a first intermediate winding, a second intermediate winding, and an outer winding, a first metal electrode layer arranged on one side of the winding body, and a second metal electrode layer arranged on the other side of the winding body, wherein the second intermediate winding is formed by winding a dielectric film around the outer circumferential surface of the first intermediate winding, the dielectric film having a pair of arc shield metal patterns formed to be spaced apart from each other on the surface of the second intermediate winding and one arc shield metal pattern being connected to the first metal electrode layer and the other arc shield metal pattern being connected to the second metal electrode layer.