Ceramic Collective Board Layout for Inner Electrode Alignment
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Solution Overview
Problem
Existing methods for manufacturing multilayer electronic components using ceramic collective boards often result in misalignment of inner electrodes, leading to variations in electrode lengths and dimensions, which affects the quality and consistency of the final product.
Innovation Solution
The use of a first-stage ceramic collective board with specifically designed gaps and cutouts between inner electrodes, allowing for accurate alignment and cutting to ensure consistent electrode lengths, and a manufacturing method that involves forming and cutting these boards to create a second-stage ceramic collective board for precise electrode placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ceramic green sheets are stacked at high speed to improve productivity, then manufacturing efficiency increases, but misalignment of inner electrodes occurs due to displacement of ceramic green sheets
Solution Approach 1:
The patent divides the ceramic collective board into multiple sections with positioning marks at regular intervals, allowing for modular alignment verification. This segmentation enables high-speed stacking while maintaining precision by checking alignment at discrete points rather than requiring perfect alignment across the entire board.
Solution Approach 2:
Positioning marks are formed on the ceramic green sheets before stacking, and alignment verification is performed in advance of final assembly. This preliminary positioning action ensures that even high-speed stacking processes can detect and correct misalignment before it affects the final product quality.
2Manufacturing precision
If cutting positions are determined using X-ray imaging to ensure precision, then inner electrode position accuracy improves, but device complexity and cost increase due to large-scale equipment requirements
Solution Approach 1:
The patent uses positioning marks as simplified copies or representations of the inner electrode positions. Instead of imaging the actual electrodes, the positioning marks serve as surrogate indicators that can be read with simple optical systems, replacing complex X-ray imaging equipment with more accessible and cost-effective devices.
Solution Approach 2:
The positioning marks are simple, inexpensive features formed on the ceramic surface that serve their purpose during alignment and cutting operations. These marks are disposable indicators that enable precise cutting without requiring expensive, complex imaging equipment.
3Manufacturing precision
If positioning marks are formed on ceramic green sheets before stacking to improve alignment, then inner electrode position accuracy improves, but manufacturing process complexity increases
Solution Approach 1:
The positioning marks are formed during the same printing process used for applying inner electrode patterns, combining two functions into one operation. This merging eliminates the need for separate positioning mark formation steps, reducing process complexity while maintaining alignment accuracy.
Solution Approach 2:
The positioning marks serve multiple functions: they guide alignment during stacking, enable verification of inner electrode positions, and provide reference for cutting operations. This multi-functionality reduces the need for separate features or processes for each function, simplifying the overall manufacturing process.
Data Source
AI summary
Even with the occurrence of misalignment of inner electrodes in a ceramic collective board, a multilayer electronic component is made in which inner electrodes are disposed at suitable positions. Disclosed herein are descriptions of a first-stage ceramic collective board and a second-stage ceramic collective board used for manufacturing a multilayer electronic component. The present disclosure further describes a manufacturing method for the second-stage ceramic collective board and a manufacturing method for a multilayer electronic component.