Multilayer Solid Aluminum Capacitor Core for High-Voltage Isolation
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Solution Overview
Problem
The existing process for preparing multilayer solid aluminum electrolytic capacitors results in poor voltage-resistant performance due to poor repair performance of the dielectric layer on the cutting side of the aluminum foil, leading to inconsistencies in alumina film thickness, denseness, and homogeneity, which causes local short-circuits and increased leakage current.
Innovation Solution
A core structure is designed with insulating plates bonded to both sides of the aluminum foil, featuring hollow portions and conductive layers, along with a U-shaped insulating adhesive layer to separate anode and cathode zones, and a conductive frame for electrical connections, ensuring consistent dielectric layer formation and preventing short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the existing reformation process is used to repair the dielectric layer on the cutting side of aluminum foil, then the manufacturing process can be completed, but the voltage-resistant performance deteriorates due to poor repair quality and alumina film inconsistency
Solution Approach 1:
The patent removes the problematic reformation process step entirely. Instead of attempting to repair the dielectric layer through reformation, the invention uses a barrier adhesive layer applied directly to the cathode zone to prevent alumina film defects from occurring in the first place, thereby extracting the harmful reformation operation from the manufacturing process
Solution Approach 2:
The barrier adhesive layer is applied in advance before any potential damage can occur. This preliminary protective measure prevents the formation of defects on the cutting side alumina film, eliminating the need for subsequent reformation repairs and ensuring consistent dielectric quality from the outset
2Ease of manufacture
If cutting is performed on aluminum foil with high formation voltage, then the cathode zone can be separated, but deep cracks occur in the alumina film layer due to high brittleness, leading to local short-circuits
Solution Approach 1:
The barrier adhesive layer serves as a cushioning protective layer applied before the cutting operation. This layer compensates for the brittleness of the high-voltage alumina film during cutting, preventing deep cracks from forming and thereby cushioning against the risk of local short-circuits that would otherwise occur during the separation process
3Volume of moving object
If multilayer cores are stacked in parallel with surface mounting technology, then miniaturization and light weight are achieved, but the complexity of ensuring consistent layer formation increases
Solution Approach 1:
The barrier adhesive layer is selectively applied only to the cathode zone where the cutting operation occurs, rather than uniformly across the entire aluminum foil. This localized approach addresses the specific problem area without adding unnecessary complexity to the overall multilayer stacking process, maintaining manufacturing simplicity while ensuring layer consistency in the critical region
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 voltage resistance and reduces the risk of product failure by maintaining consistent dielectric layer properties and preventing short-circuits, thereby improving the reliability and performance of high-voltage multilayer solid aluminum electrolytic capacitors.
Implementation Method 1
rectangular insulating plates bonded to both sides of the aluminum foil
Implementation Method 2
conductive polymer, carbon, and silver paste layers are applied
Implementation Method 3
U-shaped insulating adhesive layer to prevent short-circuits
Implementation Method 4
sequential stacking and encapsulation with a resin casing
Data Source
AI summary
A core includes an aluminum foil, a first insulating plate and a second insulating plate. The first insulating plate and the second insulating plate are insulatedly bonded to opposite two sides of the aluminum foil, respectively. A middle of each of the first insulating plate and the second insulating plate is provided with a rectangular hollow portion. A surface of the hollow portion is sequentially provided with a conductive polymer layer, a conductive carbon paste layer and a conductive silver paste layer from inside to outside. A multilayer solid aluminum electrolytic capacitor, including N cores, a conductive frame, a rivet, a substrate and a resin casing, is also provided. This application also provides a method for preparing the multilayer solid aluminum electrolytic capacitor.