Monolithic Ceramic Component Delamination Prevention via Localized Pressing
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Solution Overview
Problem
The increasing density difference between inner electrodes in opposite and extension regions of monolithic ceramic electronic components leads to delamination issues and poor mounting stability due to uneven pressing pressure.
Innovation Solution
A manufacturing method involving a first pressing with an elastic sheet and a second pressing with a rigid body, using a rubber sheet and varying Si and Mn content in ceramic layers to enhance adhesion and prevent delamination, while maintaining the structural integrity of the ceramic multilayer body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of stacking of inner electrodes is increased to achieve miniaturization and increased electrostatic capacities, then the electrostatic capacity increases, but the density difference between opposite region and extension region becomes large causing delamination
Solution Approach 1:
The patent applies different pressing pressures to different regions of the ceramic multilayer body. Specifically, the extension region (where inner electrode density is low) receives a larger pressing pressure than the opposite region (where inner electrode density is high). This local differentiation of pressing pressure compensates for the density imbalance and prevents delamination in the extension region while maintaining overall structural integrity.
2Reliability
If isostatic pressing is applied to prevent delamination, then delamination does not occur easily, but the corner portions become rounded causing tombstone phenomenon
Solution Approach 1:
The patent uses a pressing device with differentiated pressing surfaces that apply different pressures to different regions. The pressing surface has a first pressing portion for the opposite region and a second pressing portion for the extension region, where the second portion applies greater pressure. This localized pressure application prevents delamination in the extension region without causing excessive rounding of corner portions, thereby avoiding the tombstone phenomenon during mounting.
3Ease of manufacture
If pressing pressure is applied uniformly to the ceramic multilayer body, then the manufacturing process is simple, but the extension region with low inner electrode density does not receive sufficient pressure causing delamination
Solution Approach 1:
The patent employs a pressing device with a pressing surface that has spatially varying pressing capabilities. The pressing surface includes a first pressing portion corresponding to the opposite region and a second pressing portion corresponding to the extension region. The second pressing portion is designed to apply a larger pressing pressure than the first pressing portion, thereby providing the additional pressure needed in the extension region where inner electrode density is low, while maintaining a relatively simple overall manufacturing process.
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
The method effectively prevents delamination and enhances mounting stability by ensuring uniform pressure distribution and adhesion between inner electrodes and ceramic layers, reducing the occurrence of the tombstone phenomenon.
Implementation Method 1
performing a first pressing by pressing the mother inner layer block from above the mother ceramic inner portion in the stacking direction
Implementation Method 2
performing a second pressing by pressing the second mother ceramic outer layer in the stacking direction to form a mother multilayer body
Data Source
AI summary
A method for manufacturing a monolithic ceramic electronic component includes the steps of preparing a first ceramic outer layer, stacking a plurality of inner electrodes and a plurality of ceramic green sheets on the first ceramic outer layer, forming an inner portion, applying first pressing in the stacking direction, forming an outer portion on the inner portion to form a second ceramic outer layer, applying second pressing in the stacking direction to form a multilayer body, cutting the mother multilayer body to obtain individual multilayer bodies, sintering the individual multilayer bodies to obtain ceramic bodies, and forming first and second outer electrodes on the outer surface of each of ceramic bodies.