Insulating Layer Alkali Oxide Control for High-Temperature Voltage Stability
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Solution Overview
Problem
Existing composite materials lack enhanced withstanding voltage properties at high temperatures, particularly in electronic devices, where insulation breakdown occurs due to high alkali oxide content leading to thermal breakdown and leakage currents.
Innovation Solution
A filler structure comprising a substrate, a conductive filler layer with a matrix material and insulating layer having a glass transition temperature of 400 °C or higher, and a protection layer with a low alkali oxide content, preventing oxidation and leakage currents, and including glass frit for improved adhesion and thermal expansion matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an insulating layer with high alkali oxide content is used, then the ease of manufacture is improved, but the withstanding voltage property at high temperature deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the alkali oxide content to 7% or less in the insulating layer. This quantitative parameter adjustment resolves the contradiction by maintaining manufacturability while significantly improving withstanding voltage properties at high temperatures, preventing thermal breakdown and leakage currents that occur with higher alkali oxide content.
Solution Approach 2:
The patent uses composite materials by form the insulating layer from glass frit with specific composition (containing 7% or less alkali oxide). This composite approach combines multiple oxides in controlled proportions to achieve both manufacturability and enhanced high-temperature electrical insulation properties, resolving the trade-off between ease of manufacture and reliability.
2Strength
If a glass frit with high alkali oxide content is used in the insulating layer, then the adhesion is improved, but the thermal breakdown resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the alkali oxide content to 7% or less in the glass frit composition. This precise parameter control maintains sufficient adhesion strength while dramatically improving thermal breakdown resistance, preventing the insulation breakdown that occurs with higher alkali oxide content at elevated temperatures.
3Reliability
If the glass transition temperature of the insulating layer is increased to 400 °C or higher, then the withstanding voltage property at high temperature is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The patent applies parameter changes by setting the glass transition temperature to 400 °C or higher through controlled glass frit composition (with 7% or less alkali oxide). This parameter adjustment improves withstanding voltage properties at high temperatures while maintaining reasonable manufacturability through established glass frit processing techniques.
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 enhances the withstanding voltage properties at high temperatures by preventing insulation breakdown and maintaining electrical stability, ensuring reliable operation even at 400 °C or higher temperatures.
Implementation Method 1
an insulating layer arranged between the substrate and the electrode, and having an alkali oxide of a content rate of 7% or less
Implementation Method 2
At least one of the insulating layer and the matrix material layer may include a glass frit
Implementation Method 3
a protection layer configured to contact the substrate and prevent the substrate from being oxidized
Implementation Method 4
The filler layer may include a material that generates heat in response to an electrical signal
Implementation Method 5
A glass transition temperature of the insulating layer may be 400 °C or higher
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
A filler structure includes a substrate, a filler layer spaced apart from the substrate and comprising a matrix material layer and a plurality of conductive fillers, an electrode configured to contact the filler layer and provide an electrical signal to the filler layer, and an insulating layer arranged between the substrate and the electrode, and having an alkali oxide of a content rate of 7% or less.