Film Capacitor Electrode Protrusions for Stronger Laminate Bonding
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Solution Overview
Problem
Existing film capacitors have insufficient mechanical strength at the contact points between the metallized film and the external electrodes.
Innovation Solution
The film capacitor design includes external electrodes with protrusions that extend beyond the thickness of the dielectric films, enhancing the bonding strength by increasing the contact area between the laminate and the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the external electrode is made flat without protrusions, then the device complexity is reduced, but the bonding strength between the electrode and laminate is insufficient
Solution Approach 1:
The external electrode incorporates protrusions that extend in the width direction beyond the laminate edges, adding a dimensional feature to increase contact area. This dimensional change transforms a simple flat electrode into one with protruding contact points, thereby improving bonding strength without significantly complicating the overall device structure
2Strength
If the protrusion width is increased to improve bonding strength, then the mechanical strength of contact portions is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
The invention specifies that protrusion ends extend beyond the laminate edges by a controlled distance (0.1mm to 5mm in preferred embodiments). This parameter change defines an optimal range that ensures sufficient bonding area while remaining manufacturable with standard tolerances, balancing mechanical strength improvement with manufacturing feasibility
3Strength
If the contact area between electrode and laminate is increased, then the bonding strength is improved, but the amount of electrode material required increases
Solution Approach 1:
The external electrode is segmented into multiple protrusions distributed across the laminate surface, rather than using a single large continuous electrode. This segmentation increases the total contact area and bonding strength while using less overall electrode material, as the protrusions are concentrated at critical contact points rather than covering the entire surface
Data Source
AI summary
A film capacitor that includes: a laminate including a first dielectric film, a second dielectric film, a first metal layer, and a second metal layer laminated in a laminate direction; a first external electrode on a first end surface of the laminate in a width direction perpendicular to the laminate direction and connected to the first metal layer; and a second external electrode on a second end surface of the laminate in the width direction, the first external electrode having first protrusions arranged in the laminate direction and protruding toward the second external electrode in the width direction, at least one of the first protrusions of the first external electrode having a first protrusion end with a width greater than a total thickness of the first dielectric film and the second dielectric film by two times or more.