Laminated Ceramic Capacitor Side Gap Measurement via Plated Electrodes
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Solution Overview
Problem
The challenge is to accurately measure the side gap between the end surface of a ceramic base body and internal electrodes in laminated ceramic capacitor arrays, as small gaps lead to reduced adhesiveness and increased risk of moisture ingress causing short circuits, while existing methods suffer from reduced measurement accuracy and cumbersome operations due to large designed gaps.
Innovation Solution
A production method involving the formation of external terminal electrodes by plating on the ceramic base body, allowing for accurate measurement of the side gap by determining the distance between the external terminal electrodes and the end surface, enabling efficient detection and removal of defective ceramic base bodies with minimized size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the side gap between the capacity section and end surfaces of the ceramic base body is reduced to increase internal electrode areas, then the capacity increases and size reduction is achieved, but the adhesiveness between ceramic layers decreases and moisture can easily reach the internal electrodes causing short circuit failures
Solution Approach 1:
The invention divides the side gap measurement into two separate measurements: the first side gap G1a from the end surface to the internal electrode, and the second side gap G1b from the internal electrode to the capacity section. This segmentation allows independent optimization of each gap portion, enabling the total side gap to be minimized while maintaining sufficient adhesiveness and moisture protection in each segment.
Solution Approach 2:
The invention performs preliminary measurement of the first side gap G1a from the end surface to the internal electrode before final assembly. This preliminary measurement allows the side gap to be controlled within a predetermined range to ensure adequate adhesiveness and moisture resistance, preventing short circuit failures before they occur.
2Reliability
If the side gap is designed to be large to ensure adequate adhesiveness and moisture protection, then reliability improves, but the area of internal electrodes decreases and component size cannot be reduced
Solution Approach 1:
The invention segments the total side gap into two measurable portions (G1a and G1b), allowing the first portion G1a to be precisely controlled for reliability while minimizing the second portion G1b to maximize internal electrode area. This segmentation resolves the contradiction by enabling differentiated optimization of each gap segment.
Solution Approach 2:
The invention replaces manual observation and measurement of exposed internal electrode portions with an automated optical measurement system that measures the distance from the end surface to the external terminal electrode. This substitution enables accurate measurement of the first side gap G1a, allowing the side gap to be minimized while maintaining reliability through precise control.
3Measurement precision
If the exposed portions of internal electrodes are observed with an image pickup device to measure the side gap, then measurement can be performed, but measurement accuracy is reduced and the operation becomes cumbersome due to the relatively small size of exposed portions
Solution Approach 1:
Instead of directly measuring the small exposed portion of the internal electrode, the invention measures the distance from the end surface to the external terminal electrode (first side gap G1a). This inverted measurement approach measures a larger, more easily observable distance that can be accurately captured by the image pickup device, thereby improving both measurement accuracy and operational ease.
Solution Approach 2:
The invention uses the external terminal electrode as an intermediary reference point for measurement. By measuring the distance from the end surface to the external terminal electrode rather than directly measuring the small internal electrode exposure, the measurement process becomes more accurate and less cumbersome, as the external terminal electrode provides a larger, more distinct measurement target.
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 method enables precise measurement and efficient removal of defective components, allowing for smaller side gaps and increased flexibility in measurement directions, thereby reducing the size of the ceramic base body and minimizing the risk of short circuits.
Implementation Method 1
forming substantially belt-shaped external terminal electrodes on the first side surface by plating, the external terminal electrodes having lower plating films electrically connected to the exposed portions of the internal electrodes
Data Source
AI summary
In a production method for a laminated electronic component, a ceramic base body is formed by stacking a plurality of ceramic layers, and internal electrodes are formed in the ceramic base body. Lead-out portions of the internal electrodes are exposed from side surfaces of the ceramic base body. Belt-shaped external terminal electrodes are formed on the side surfaces by plating so as to be electrically connected to the exposed portions of the internal electrodes. The distance from an end surface to an external terminal electrode closest to the end surface in the ceramic base body is measured. When the measured distance does not correspond to a predetermined reference value, the ceramic base body is removed as being defective.