Polygonal Unit Capacitor Structure for Higher Packing Density
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Solution Overview
Problem
Multilayer capacitors face limitations in capacitance per unit volume due to decreased breakdown voltage and structural constraints, particularly when arranged in a circular cross-section, leading to reduced packing density and capacitance.
Innovation Solution
The development of a capacitor component with unit devices having a polygonal cross-section, allowing for increased packing density and higher capacitance per unit volume by eliminating spaces between adjacent units and optimizing the arrangement of internal electrodes and dielectric films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular cross-section capacitors are arranged, then manufacturing is simple, but spaces are generated between adjacent capacitors reducing packing density
Solution Approach 1:
The patent applies the inverse of spheroidality by using polygonal (flat-sided) cross-sections instead of circular ones. This geometric change allows adjacent capacitors to fit together more tightly, eliminating the spaces that occur with circular arrangements and thereby increasing packing density while maintaining manufacturability through standard stacking processes.
2Quantity of substance
If multilayer capacitors are miniaturized with thinner dielectric layers, then capacitance per unit volume increases, but breakdown voltage decreases
Solution Approach 1:
The patent changes the geometric parameter of the capacitor cross-section from circular to polygonal. This parameter change increases the effective packing density and capacitance per unit volume without requiring further thinning of the dielectric layer, thereby maintaining the breakdown voltage while achieving higher capacitance density through optimized spatial arrangement.
3Quantity of substance
If polygonal cross-section capacitors are used, then packing density and capacitance per unit volume increase, but manufacturing complexity increases
Solution Approach 1:
The patent segments the capacitor structure into modular unit devices with polygonal cross-sections that can be stacked using standard processes. Each unit device is independently formed with internal electrodes and dielectric layers, allowing the complex polygonal geometry to be achieved through repeated modular assembly rather than complex monolithic fabrication.
Data Source
AI summary
A capacitor component includes a body including a capacitance formation portion including a plurality of unit devices including a first internal electrode, a first dielectric film surrounding the first internal electrode, and a second internal electrode surrounding the first dielectric film, and a molded portion surrounding the capacitance formation portion, first and second external electrodes respectively disposed on a first surface and a second surface of the body opposing each other in a first direction to be respectively connected to the first and second internal electrodes. Cross-sections perpendicular to the first direction of at least two of the plurality of unit devices have a polygonal shape.