Laminated Ceramic Package Cavity Dimensional Accuracy
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Solution Overview
Problem
Laminated ceramic packages face challenges in securing dimensional accuracy of cavities due to uneven firing shrinkage, as constraint layers do not effectively contact the inner parts of the cavity, leading to accuracy differences between green sheets.
Innovation Solution
A laminated ceramic package design incorporating a first ceramic layer with a flake-type ceramic filler and glass, and a second ceramic layer with a different firing shrinkage rate, where the first layer serves as a constraint to suppress horizontal shrinkage of the second layer during firing, ensuring precise cavity dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If constraint layers are formed on the upper and lower surfaces of the laminated body to suppress horizontal shrinkage during firing, then vertical shrinkage is allowed and firing is enabled, but the constraint layers do not contact the inner parts of the cavity, causing uneven shrinkage suppression and dimensional inaccuracy in the cavity
Solution Approach 1:
The invention divides the constraint function into multiple segments by forming protrusions at regular intervals on the constraint layer, which contact different regions of the green sheet including cavity areas. This segmentation allows uniform shrinkage suppression across the entire surface without requiring continuous constraint layer contact.
Solution Approach 2:
The constraint layer is designed with locally differentiated features: protrusions in cavity regions provide localized constraint contact, while other areas maintain the base constraint layer structure. This local quality variation ensures accurate cavity dimensions without over-constraining the entire structure.
2Manufacturing precision
If the laminated body is pressed during firing to prevent horizontal shrinkage, then vertical shrinkage is permitted, but the green sheets in regions not contacting the constraint layer shrink unevenly, reducing manufacturing precision
Solution Approach 1:
The constraint layer with protrusions is formed before the firing process, establishing predetermined contact points that will guide uniform shrinkage during firing. This preliminary structuring ensures that when firing occurs, the green sheets are already positioned to shrink uniformly without requiring complex real-time control.
Solution Approach 2:
The invention changes the physical parameters of the constraint layer by forming protrusions with specific heights and spacing, transforming it from a flat continuous layer to a structured array. This parameter modification enables the constraint layer to effectively contact and control shrinkage in cavity regions while maintaining ease of manufacture through standard ceramic processing.
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 design allows for precise adjustment and control of cavity dimensions by minimizing horizontal shrinkage, thereby enhancing the accuracy and reliability of the ceramic package.
Implementation Method 1
a first ceramic layer on the laminated ceramic substrate having a firing area shrinkage rate of about 1% or less; and a second ceramic layer on the first ceramic layer, having a cavity receiving electronic components and a different firing shrinkage rate from the first ceramic layer
Data Source
AI summary
Provided is a laminated ceramic package. The laminated ceramic package includes a laminated ceramic substrate having a conductive pattern therein, a first ceramic layer on the laminated ceramic substrate, and a second ceramic layer on the first ceramic layer. The first ceramic layer has a firing area shrinkage rate of about 1% or less. The second ceramic layer has a cavity receiving electronic components and a different firing shrinkage rate from the first ceramic layer.