Slit-Sealed Capacitor Element for Delamination and ESR Control
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Solution Overview
Problem
Existing capacitor elements experience delamination issues in the effective capacitance portion, which can lead to deterioration of ESR (Equivalent Series Resistance), despite the inclusion of stress relaxation layers.
Innovation Solution
A capacitor element design featuring an anode plate with a core and porous parts, a dielectric layer on the porous parts, and a cathode layer, sealed by a sealing layer with slits on its surface, positioned to avoid contact with the cathode layer and extended conductors, reducing stress and delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a stress relaxation layer is disposed between the capacitor element and sealing layer, then stress acting between the inside and outside of the capacitor array is reduced, but delamination may still occur in the effective capacitance portion
Solution Approach 1:
The sealing layer is divided into a first sealing layer and a second sealing layer that are disposed on opposite major faces of the capacitor element. This segmentation allows each sealing layer to independently manage stress distribution, preventing delamination while maintaining stress reduction benefits.
Solution Approach 2:
The invention transitions from a single-layer sealing structure to a multi-layer sealing structure with layers disposed on opposite faces of the capacitor element. This dimensional change enables comprehensive stress management from both sides, effectively preventing delamination in the effective capacitance portion.
2Reliability
If the sealing layer is made continuous and intact, then sealing performance is improved, but stress concentration may occur leading to delamination
Solution Approach 1:
The sealing layer is segmented into multiple layers (first sealing layer and second sealing layer) disposed on opposite faces. This segmentation distributes stress across multiple interfaces rather than concentrating it in a single continuous layer, preventing delamination while maintaining sealing integrity.
Solution Approach 2:
Each sealing layer is designed with specific local properties optimized for its position. The first sealing layer on the first major face and the second sealing layer on the second major face can have different characteristics tailored to their respective stress environments, allowing effective stress management without compromising overall sealing performance.
Data Source
AI summary
A capacitor element that includes: a capacitor part including: an anode plate having a core and a porous part on at least one major face of the core, a dielectric layer on a surface of the porous part, and a cathode layer on a surface of the dielectric layer; and a sealing layer that seals the capacitor part, wherein a surface of the sealing layer has a slit.