Multilayer Ceramic Capacitor Side Margins for Miniature Punchout
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Solution Overview
Problem
The miniaturization of multilayer ceramic capacitors makes it difficult to obtain sufficient shear force to punch out ceramic sheets for forming side margin parts, which is essential for protecting side surfaces and maintaining capacitance.
Innovation Solution
A multilayer ceramic electronic device with a ceramic main body having laminated internal electrodes and side margin parts that cover the side surfaces, where the width dimension is greater than the length dimension, allowing for effective formation of side margin parts even at small dimensions, and a method involving punching out ceramic sheets to form these parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the laminated bodies are miniaturized to meet compact electronic device demands, then the size of multilayer ceramic capacitors is reduced, but the shear force becomes insufficient to punch out ceramic sheets for forming side margin parts
Solution Approach 1:
The patent changes the orientation relationship between the laminated body and ceramic sheet from conventional vertical arrangement to horizontal arrangement. The ceramic sheet is placed horizontally on the side surface of the laminated body, and the punchout process occurs in the horizontal direction. This dimensional reconfiguration allows sufficient shear force to be generated even in miniaturized capacitors, resolving the contradiction between size reduction and punching force sufficiency.
2Manufacturing precision
If side margin parts are attached later in the manufacturing process to protect side surfaces, then miniaturization and increased capacitance are achieved, but the punchout process becomes difficult at small dimensions
Solution Approach 1:
The patent performs the punchout process for forming side margin parts at an earlier stage in the manufacturing process, before the capacitors are fully assembled and miniaturized. By preparing the side margin parts through punchout while the laminated bodies are still in a more manageable state, the process becomes easier to execute. The ceramic sheets are punched out to form side margin parts that are then attached to protect the side surfaces, achieving both manufacturing ease and manufacturing precision.
3Ease of manufacture
If the width dimension is made greater than the length dimension, then effective formation of side margin parts is enabled at small dimensions, but the conventional dimensional configuration is changed
Solution Approach 1:
The patent intentionally creates an asymmetric dimensional configuration where the width dimension (W) is greater than the length dimension (L) of the multilayer ceramic capacitor. This asymmetric arrangement is specifically designed to facilitate the punchout process for forming side margin parts. The larger width dimension provides sufficient space for the ceramic sheet to be effectively punched out and attached, enabling side margin part formation at small dimensions while accepting the unconventional asymmetric geometry.
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
Enables the effective formation of side margin parts at small dimensions while maintaining capacitance, facilitating miniaturization and increased capacitance in multilayer ceramic capacitors.
Implementation Method 1
the smaller the laminated bodies become in response to the demand for miniaturization, the more difficult it becomes to obtain sufficient shear force for the side surfaces of the laminated bodies to punch out a ceramic sheet
Data Source
AI summary
A method for manufacturing a multilayer ceramic electronic device includes punching out a ceramic sheet by one of left and right side surfaces of a laminated body so as to form a side margin part on the one of the left and right side surfaces of said laminated body; and punching out another ceramic sheet by another of the left and right side surfaces of the laminated body so as to form a side margin part on the another of the left and right side surfaces of said laminated body, thereby forming a ceramic main body having the laminated body and the pair of side margin parts that respectively cover the left and right side surfaces of the laminated body. The width W is greater than the length L in the multilayer ceramic electronic device.