Laminated Ceramic Capacitor Step Absorption Design
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Solution Overview
Problem
Laminated ceramic capacitors experience dimensional distortion due to steps between internal electrodes and ceramic substrate ends, leading to improper mounting and complicating the manufacturing process, with existing solutions requiring high-precision printing and risking sheet attack.
Innovation Solution
A laminated ceramic capacitor design where internal electrodes are stacked with alternating spacings and led out to opposite ends, with one surface being planar, and a specific ratio of distances (Db/Da ≤ 2.1) to absorb steps, eliminating the need for ceramic paste printing and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ceramic paste is printed around internal electrodes to absorb steps, then dimensional distortion is reduced, but manufacturing process complexity increases and sheet attack risk occurs
Solution Approach 1:
The invention extracts and eliminates the problematic ceramic paste printing step from the manufacturing process. Instead of adding paste to absorb steps, the design modifies the internal electrode configuration itself (using alternating spacing patterns) to inherently absorb the steps, thereby removing the source of manufacturing complexity and sheet attack risks while maintaining dimensional stability
Solution Approach 2:
The internal electrodes are designed to serve dual functions: their primary electrical function and their step-absorbing function. By configuring electrodes with alternating spacings (first spacing at ends, second spacing at center), the electrodes themselves absorb the steps during lamination, eliminating the need for separate step-absorbing materials and simplifying the manufacturing process
2Manufacturing precision
If ceramic paste is printed around internal electrodes to absorb steps, then dimensional distortion is reduced, but sheet attack occurs due to solvent penetration
Solution Approach 1:
The invention removes the ceramic paste material from the structure entirely, eliminating the solvent that causes sheet attack. The step-absorbing function is achieved through the geometric configuration of internal electrodes with alternating spacings, which inherently accommodate the steps without requiring additional materials that could harm the green sheet-PET film bonding
Solution Approach 2:
The internal electrodes with alternating spacings act as an intermediary structure that absorbs the steps between the green sheets during lamination. This mediator function is performed by the electrode geometry itself rather than by a separate material layer, preventing solvent-related sheet attack while maintaining dimensional control
3Ease of manufacture
If internal electrodes are stacked with alternating spacings to absorb steps, then manufacturing process is simplified, but manufacturing precision may be compromised
Solution Approach 1:
The invention changes the spacing parameters of internal electrodes (alternating between first spacing at end portions and second spacing at center portions) to absorb steps. This parameter variation is built into the electrode design itself, allowing standard manufacturing processes to produce capacitors with minimized dimensional distortion without requiring additional precision-control steps
Data Source
AI summary
A laminated ceramic capacitor includes a ceramic substrate and a plurality of internal electrodes. The ceramic substrate is of a shape defined by length, width and thickness directions. The internal electrodes are stacked one over another within the ceramic substrate at spaced intervals in the thickness direction and alternately led out to opposite ends of the ceramic substrate in the length direction. The ceramic substrate has opposite surfaces in the thickness direction, one of which is planar. In the laminated ceramic capacitor, 1<Db/Da≦2.1, where Da represents a distance between the planar surface and an outermost internal electrode at a center between the opposite ends of the ceramic substrate, and Db represents a distance between the planar surface and the outermost internal electrode at one of the opposite ends of the ceramic substrate.