Capillary-Filled Insulation Cavities in Multilayer Piezoactuators
Solution Overview
Problem
Existing methods for producing electric components, such as multilayer piezoactuators, struggle with ensuring effective electrical insulation and mechanical stress relief, leading to potential short circuits and uncontrolled crack propagation due to inadequate insulation and mechanical weaknesses.
Innovation Solution
A method involving the creation of cavities within the component body, which are filled with insulation material using capillary forces, serving as both insulation zones and predetermined breaking regions to prevent electrical breakdowns and mechanical stress, while allowing for controlled etching and external contacting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation zones are formed by etching methods and filled with insulation material, then electrical insulation is improved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent extracts the insulation material filling step from the traditional multi-step process by using cavities that are already present in the multilayer component body. These cavities are formed during the sintering process itself, eliminating the need for separate etching and filling operations. The insulation material is simply placed into these pre-formed cavities, significantly simplifying the manufacturing process while maintaining effective electrical insulation.
Solution Approach 2:
The cavities for insulation are created in advance during the sintering process of the multilayer component, before the insulation material is introduced. This preliminary formation of cavities eliminates the need for subsequent etching operations and allows for efficient insulation material placement, reducing overall manufacturing complexity and time.
2Reliability
If cavities are introduced into the body to serve as insulation zones, then electrical breakdown voltage is enhanced, but the body structure becomes more complex
Solution Approach 1:
The cavities in the multilayer component serve multiple functions simultaneously: they provide electrical insulation between adjacent electrode layers, act as stress relief zones to prevent mechanical failures, and serve as predetermined breaking regions for controlled crack propagation. This multi-functionality enhances electrical breakdown voltage while avoiding the need for separate structural modifications.
Solution Approach 2:
The patent utilizes a porous or cavity-containing structure within the multilayer component body. These cavities are strategically positioned to provide electrical insulation pathways while maintaining the overall structural integrity. The porous nature of these regions allows for insulation material placement and provides stress relief without significantly complicating the external body shape.
3Duration of action of stationary object
If cavities are used for stress relief and predetermined breaking regions, then mechanical durability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent combines the formation of cavities with the sintering process of the multilayer component. Instead of creating cavities through separate precision machining or etching operations, the cavities are formed integrally during sintering by controlling the green body structure or using sacrificial materials. This merging of processes reduces manufacturing precision requirements while ensuring proper cavity positioning for stress relief and controlled breaking.
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 approach enhances the electric breakdown voltage, reduces the risk of short circuits, and provides mechanical relief by creating targeted crack propagation points, thereby improving the reliability and durability of the electric components.
Implementation Method 1
The cavity is at least partly filled with an insulation material by means of capillary forces
Data Source
AI summary
A method for producing an electric component (19) is specified, wherein in a step A) a body (1) having at least one cavity (7, 8) is provided. In a step B), the cavity (7, 8) is at least partly filled with a liquid insulation material (13) by means of capillary forces. Furthermore, an electric component (19) is specified wherein a cavity (7, 8) is at least partly filled with an insulation material (13). The insulation material (13) is introduced into the cavity (7, 8) by means of capillary forces. Furthermore, an electric component (19) is specified wherein a cavity (7, 8) is at least partly filled with an organic insulation material (13) and wherein the cavity is at least partly covered by a fired external contacting (17, 18).