Multilayer Ceramic Component Alignment With Low Residual Magnetization

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Solution Overview

Problem

Existing methods for aligning multilayer ceramic components, such as capacitors, are time-consuming and can cause magnetization, particularly when using magnets to align internal electrodes orthogonal to the accommodation spaces, leading to inefficiencies and potential component magnetization.

Innovation Solution

A method involving a nonmagnetic holder with recesses and a magnetic field perpendicular to the component's longitudinal axis is used to align multilayer components, allowing rapid orientation adjustment and minimizing residual magnetization by using a controlled magnetic field and vibration techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If magnets are used to align internal electrodes orthogonal to the accommodation spaces, then alignment of multilayer components is achieved, but alignment time increases and component magnetization occurs

Engineering Contradiction:

Improvealignment precisionVSAvoidalignment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Instead of using magnets to directly align components (conventional method), the invention inverts the approach by using a nonmagnetic holder with recesses that mechanically constrain components to specific orientations, eliminating the need for time-consuming magnetic alignment while preventing component magnetization

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention replaces the magnetic field-based alignment system with a mechanical constraint system consisting of a nonmagnetic holder with precisely engineered recesses that guide and fix component orientation through physical geometry rather than magnetic forces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If magnets are used to align internal electrodes, then alignment is achieved, but component magnetization occurs as a harmful side effect

Engineering Contradiction:

Improvealignment precisionVSAvoidcomponent magnetization

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The invention extracts and eliminates the magnetic field source (magnets) from the alignment process, using only a nonmagnetic holder with geometric recesses to achieve alignment, thereby completely removing the harmful side effect of component magnetization while preserving alignment precision

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The nonmagnetic holder with recesses serves as an intermediary mechanism that enables precise alignment without direct magnetic interaction with the components, acting as a mediator that achieves the alignment function without causing harmful magnetization

Inventive Principle:

Principle #24Intermediary (Mediator)

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 significantly reduces alignment time and minimizes component magnetization, ensuring precise and efficient alignment of multilayer components like ceramic capacitors, piezoelectric elements, and other ferromagnetic layers.

Implementation Method 1

causing a magnetic field with a magnetic flux line intersecting perpendicularly with the bottom surface to act on the multilayer components in the recesses to rotate the multilayer components about longitudinal axes of the multilayer components to have the ferromagnetic layers parallel to the magnetic flux line

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS12580131B2Method for aligning multilayer components and method for manufacturing multilayer ceramic electronic components including alignment method

Publication Date: 2026.03.17 KYOCERA CORP

AI summary

Base components are placed into recesses of a holder. Each recess includes a flat bottom surface parallel to a horizontal direction. A lid is placed above the holder at a predetermined distance from the bottom surface. A magnetic field with a magnetic flux line intersecting perpendicularly with the bottom surface is caused to act on the base components in the recesses to rotate the base components about their longitudinal axes to have internal electrode layers parallel to the magnetic flux line.