Capacitor Convex Portions Prevent Interlayer Faults
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Solution Overview
Problem
Multilayer ceramic capacitors face reliability issues due to interlayer faults caused by uneven pressure distribution during the manufacturing process, leading to hole damage and increased short defect rates, especially in high-reliability applications like automotive and infotainment systems.
Innovation Solution
The capacitor component design includes a body with dielectric layers and internal electrodes, featuring convex portions on the surfaces to prevent overlap of damaged areas during stacking, ensuring that pressure is evenly distributed and hole damage is minimized, thereby reducing interlayer faults and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ceramic green sheets are stacked with aligned vacuum hole positions, then the stacking process is simple and efficient, but pressure cannot be transmitted uniformly during pressurization causing lifting and interlayer faults
Solution Approach 1:
The patent introduces asymmetric positioning of convex portions on the second surface of the capacitor body, which correspond to vacuum hole positions. By making the convex portions asymmetrically distributed rather than uniformly aligned, the patent prevents direct alignment of vacuum holes across multiple stacked sheets, thereby eliminating pressure transmission issues while maintaining stacking efficiency.
Solution Approach 2:
The patent adds a spatial dimension solution by creating convex portions that protrude from the surface at different positions. This dimensional variation in convex portion positioning across stacked sheets prevents vacuum hole alignment problems in the stacking direction, resolving the contradiction between simple stacking and reliable pressure transmission.
2Ease of manufacture
If vacuum holes are used for sucking and separating ceramic green sheets, then the separation process is efficient, but hole damage occurs and accumulates at the same position causing interlayer faults
Solution Approach 1:
The patent applies preliminary action by pre-forming convex portions at specific positions on the ceramic green sheets before stacking. These convex portions are positioned to prevent alignment of vacuum hole suction areas across multiple sheets, thereby preventing hole damage accumulation before it can occur during the stacking and pressurization process.
Solution Approach 2:
The patent applies local quality by creating localized convex portions at specific positions on the ceramic green sheets rather than uniform modifications. This localized structural change at the vacuum hole interaction points prevents hole damage accumulation while maintaining the overall integrity and quality of the ceramic sheets.
3Strength
If pressure is applied during stacking to ensure good contact between layers, then layer adhesion is improved, but uneven pressure distribution causes lifting at vacuum hole positions
Solution Approach 1:
The patent uses asymmetric positioning of convex portions to create non-uniform pressure distribution patterns that compensate for the vacuum hole effects. The asymmetric convex portions ensure that pressure is distributed more uniformly across the stacked sheets, preventing lifting at vacuum hole positions while maintaining good layer adhesion.
Solution Approach 2:
The patent changes the geometric parameters of the ceramic green sheets by adding convex portions with specific dimensions and positions. This parameter modification alters the pressure distribution characteristics during stacking, enabling uniform pressure transmission while maintaining strong layer adhesion and preventing lifting.
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
This design effectively suppresses interlayer faults and reduces short defect rates, improving the overall reliability and performance of the capacitor components by preventing the accumulation of hole damage during the manufacturing process.
Implementation Method 1
sucking a first ceramic green sheet formed on a first release film by a vacuum hole of an adsorption apparatus and separating the first ceramic green sheet from the first release film
Data Source
AI summary
A capacitor component includes: a body including a plurality of dielectric layers and a plurality of internal electrodes stacked opposingly in a first direction, and having first and second surfaces opposing each other in the first direction, third and fourth surfaces connected to the first and second surfaces and opposing each other in a second direction, and fifth and sixth surfaces connected to the first to fourth surfaces and opposing each other in a third direction; and an external electrode disposed on the body and connected to the plurality of internal electrodes. The second surface includes a plurality of convex portions spaced apart from each other.