Ceramic Component Melting Trigger Cavity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ceramic electronic components face issues with short-circuits between internal electrodes, leading to overcurrent flow, melting, and potential re-conduction or electric discharges due to narrow electrode portions, which can result in component failure.
Innovation Solution
Incorporating a melting trigger portion in the internal electrodes that melts earlier than other parts, with a cavity below to contain the melted material and prevent re-conduction, and using a material with a lower melting point for the trigger portion, along with a manufacturing method involving ink-jet printing and firing to create the ceramic and electrode layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If narrow portions are provided in internal electrodes to disconnect melted portions, then disconnection is achieved, but the melted portions may become conductive again or cause electric discharge
Solution Approach 1:
The harmful melted material is extracted from the conductive path by causing it to fall into a cavity formed in the ceramic layer. The cavity acts as a receptacle that removes the melted portions from the electrode connection path, preventing re-conduction and electric discharge between adjacent internal electrodes.
Solution Approach 2:
The cavity serves as an intermediary structure between the melting trigger portion and the adjacent internal electrodes. It receives and contains the melted material, acting as a mediator that prevents direct contact between melted portions and other electrodes, thereby eliminating the harmful effects of re-conduction and discharge.
2Ease of manufacture
If internal electrodes are made with uniform thickness, then manufacturing is simpler, but melting trigger portion cannot be formed to melt earlier
Solution Approach 1:
The internal electrode is designed with non-uniform thickness, featuring a localized thin portion that serves as the melting trigger. This local variation in geometry creates a specific region with lower thermal mass that melts earlier under overheating conditions, providing controlled disconnection capability while the rest of the electrode maintains its structural integrity.
Solution Approach 2:
The thickness parameter of the internal electrode is varied locally to create the melting trigger portion. By changing the geometric parameter (thickness) at a specific location, the thermal properties are altered, causing that region to reach melting temperature before other portions, thereby enabling controlled melting and disconnection.
3Reliability
If cavity is provided below melting trigger portion, then melted material is contained preventing re-conduction, but device structure becomes more complex
Solution Approach 1:
The cavity formation is merged with the existing ceramic layer structure during the manufacturing process. The cavity is formed as an integral part of the ceramic layer that surrounds the internal electrode, combining the protective function with the structural element rather than adding a separate component.
Solution Approach 2:
The cavity creates a localized porous or void space within the ceramic layer structure. This porous feature provides the necessary containment volume for melted material while maintaining the overall integrity and compactness of the ceramic electronic component structure.
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 design ensures secure disconnection upon short-circuit, preventing re-conduction and electric discharges, while maintaining capacitance and reducing the risk of component failure, by using a melting trigger portion and cavity configuration.
Implementation Method 1
Each of the internal electrodes includes a melting trigger portion that melts earlier than any other portion of the internal electrodes
Implementation Method 2
The cavity is provided at a position at which the cavity overlaps the melting trigger portion at least partially in a stacking direction of the internal electrodes, and is open on a melting trigger portion side
Data Source
AI summary
A ceramic electronic component includes a stack including ceramic layers and internal electrodes stacked alternately, and external electrodes provided on a surface of the stack and electrically connected to the internal electrodes. The internal electrodes include a melting trigger portion that melts earlier than any other portion. The ceramic layer adjacent to the internal electrode including the melting trigger portion includes a cavity. The cavity is provided at a position at which the cavity overlaps the melting trigger portion at least partially in a stacking direction of the internal electrodes. The cavity is open on a melting trigger portion side. A surface of at least one of the stack and the external electrodes is provided with an identifier that serves as a marker indicating use of the ceramic electronic component with the cavity vertically below the melting trigger portion.