Stress Resistant Capacitor With Elastic Insulating Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical control units (ECUs) in vehicles face challenges due to harsh environments with high temperatures, mechanical stress, and vibrations, requiring capacitors with high reliability and durability that existing capacitors fail to meet.
Innovation Solution
A capacitor design featuring a body with dielectric layers, internal electrodes, connection electrodes, and insulating layers, including a more elastic first insulating layer to absorb vibrations and a second insulating layer for protection, along with plating layers for improved mounting efficiency and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional capacitor structure is used, then the device complexity is low, but the reliability and durability under harsh environmental conditions (high temperature, mechanical stress, vibrations) are insufficient
Solution Approach 1:
The capacitor is divided into multiple functional layers including a body, first insulating layer, second insulating layer, connection electrodes, and terminal electrodes. This segmentation allows each layer to perform its specific function optimally, contributing to overall reliability without excessive complexity
Solution Approach 2:
The capacitor employs composite material structures with different insulating layers having distinct properties. The first insulating layer provides elasticity for vibration absorption, while the second insulating layer provides rigid protection, creating a composite structure that enhances reliability under harsh conditions
2Strength
If rigid protective layers are applied to protect against mechanical stress, then the strength increases, but the ability to absorb vibrations and acoustic noise decreases
Solution Approach 1:
Different regions of the capacitor have different material properties tailored to local requirements. The first insulating layer has high elasticity for vibration absorption, while the second insulating layer has high rigidity for mechanical protection. This local differentiation resolves the contradiction between strength and vibration absorption
Solution Approach 2:
The first insulating layer with high elasticity is applied beforehand to cushion and absorb vibrations and acoustic noise before they can damage the capacitor body. This preventive cushioning protects the structure while maintaining strength
3Reliability
If multiple insulating layers are added to improve moisture resistance and reliability, then the reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The insulating protection is segmented into two distinct layers applied at different stages of manufacturing. The first insulating layer is applied to the body, and the second insulating layer is applied afterward to cover exposed portions. This segmentation enables systematic manufacturing while achieving superior moisture resistance
Solution Approach 2:
The first insulating layer is applied in advance to protect the capacitor body during subsequent manufacturing steps. This preliminary protection ensures that the structure is already shielded before terminal electrodes and other components are added, simplifying the overall manufacturing process
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 capacitor provides enhanced reliability and stability under extreme conditions, reducing acoustic noise and mechanical stress while maintaining high electrical performance and long-term durability.
Implementation Method 1
A first insulating layer is disposed on an upper surface of the body, an upper surface of the first connection electrode, and an upper surface of the second connection electrode... The first insulating layer may be formed of a material having greater elasticity than that of the second insulating layer
Data Source
AI summary
A capacitor includes a body including a dielectric layer, first internal electrodes and second internal electrodes. Each of the first internal electrodes and each of the second internal electrodes are alternately disposed with the dielectric layer interposed therebetween. A first connection electrode is disposed on a first end surface of the body to connect an end of the first internal electrodes. A second connection electrode is disposed on a second end surface of the body opposite to the first end surface to connect an end of the second internal electrodes. A first insulating layer is disposed on one surface of the body. A first terminal electrode and a second terminal electrode are respectively disposed on opposing end surfaces of the first insulating layer to connect the first connection electrode and the second connection electrode, respectively. A second insulating layer is disposed on another surface of the body.