Base Metal Combination Electrode for Electronic Ceramic Components

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Solution Overview

Problem

The high cost and complex manufacturing process of silver and copper electrode materials for electronic ceramic components, which are time-consuming and require expensive equipment, do not meet the cost-performance requirements of modern electronics.

Innovation Solution

A base metal combination electrode comprising a first base metal electrode layer and a second base metal electrode layer, made from materials like aluminum, copper, zinc, nickel, or tin, applied using thermal spraying technology to improve cost-effectiveness and simplify the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silver paste or copper paste is used as electrode material, then the electrode functionality is ensured, but the cost of electrode material and equipment increases significantly

Engineering Contradiction:

Improveelectrode functionalityVSAvoidcost of electrode material and equipment

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material composition parameter of the electrode from expensive silver/copper paste to cheaper base metal paste, achieving cost reduction while maintaining functional performance through optimized paste formulation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces expensive silver and copper electrode materials with cheaper base metal materials, using cost-effective alternatives that achieve the required functionality without relying on precious metals

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If fabrography is used to apply silver paste or copper paste, then the electrode is formed, but the manufacturing process becomes complicated and time-consuming

Engineering Contradiction:

Improveelectrode formationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the firing atmosphere parameter from reducing atmosphere to oxidizing atmosphere, which simplifies the manufacturing process by eliminating the need for complex reducing atmosphere control while still achieving proper electrode formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a simpler firing process in oxidizing atmosphere instead of the complex reducing atmosphere process, reducing equipment requirements and operational complexity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If copper paste is used and fired in reducing atmosphere, then the copper electrode is formed, but large amounts of nitrogen-hydrogen are consumed and the process takes more than an hour

Engineering Contradiction:

Improvecopper electrode formationVSAvoidfiring time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent changes the firing atmosphere from reducing to oxidizing, which dramatically reduces the required firing time from over an hour to a shorter duration, while also reducing gas consumption and simplifying the process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses an oxidizing atmosphere process instead of reducing atmosphere, which reduces consumption of expensive nitrogen-hydrogen gas and shortens the processing time significantly

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 reduces production costs and improves the cost-performance of electronic ceramic components by using less expensive base metals and a simpler thermal spraying method, maintaining electrode functionality while streamlining the manufacturing process.

Implementation Method 1

using thermal spraying technology to spray the base metal electrode material to the surface of electronic ceramic chip

Methodology Applied

Scientific EffectThermal spraying:

Data Source

PatentUS9330841B2Base metal combination electrode of electronic ceramic component and manufacturing method thereof

Publication Date: 2016.05.03 LONGKE ELECTRONICS HUIYANG

AI summary

The present invention provides a base metal combination electrode of electronic ceramic component and manufacturing method thereof, wherein said base metal combination electrode comprises a first base metal electrode layer covering on two sides of said electronic ceramic chip and a second base metal electrode layer covering on said first base metal electrode layer, the manufacturing method for base metal combination electrode of electronic ceramic component comprises using thermal spray equipment to spray the electrode material to the surface of electronic ceramic chip. Comparing with using silver paste or copper paste only, it reduces the cost of electrode material without destroying the function of the electrode. The manufacturing method for base metal combination electrode of the present invention has simple technological process, high preparation efficiency and low cost, and it reduces the production cost of electrode of the electronic ceramic component on the whole.