Ceramic Insulation Layer Projections for Plating Flow Resistance

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Solution Overview

Problem

Existing ceramic components face issues with plating flow, low electrode fixing strength, and poor moisture resistance due to smooth insulation layers, leading to reduced yield and increased leak current.

Innovation Solution

A ceramic component design featuring an insulation layer with a flat portion and multiple projections, enhancing creepage distance and anchor effect for improved leakage current suppression, plating flow resistance, and moisture resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a smooth insulation layer is used, then the manufacturing process is simple, but plating flow occurs and yield is lowered

Engineering Contradiction:

Improveinsulation layer formation simplicityVSAvoidyield

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The insulation layer is designed with different surface characteristics: a flat portion for general insulation and a projection portion with protrusions for plating control. This local differentiation prevents plating flow while maintaining manufacturing feasibility through a single-layer structure formed by conventional methods.

Inventive Principle:

Principle #3Local quality

2Device complexity

If a smooth insulation layer is used, then the structure is simple, but electrode fixing strength is low

Engineering Contradiction:

Improveinsulation layer structureVSAvoidelectrode fixing strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

Protrusions are formed on the projection portion of the insulation layer surface, creating curved geometric features that increase the contact area and mechanical interlocking between the external electrode and insulation layer, thereby enhancing electrode fixing strength without complicating the overall structure.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Stability of the object's composition

If a smooth insulation layer is used, then the surface is uniform, but moisture resistance is poor due to water entry

Engineering Contradiction:

Improvesurface uniformityVSAvoidmoisture resistance

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The insulation layer surface is designed with asymmetric features: a flat portion for uniformity and a projection portion with protrusions that create an uneven surface profile. This asymmetric structure prevents water film formation and entry paths while maintaining overall surface stability.

Inventive Principle:

Principle #4Asymmetry

4Area of stationary object

If a smooth insulation layer is used, then the surface area is small, but leakage current suppression is poor

Engineering Contradiction:

Improveinsulation layer surface areaVSAvoidleakage current

Core Design Contradiction:

Area of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The insulation layer surface transitions from a two-dimensional flat surface to a three-dimensional structure with protrusions on the projection portion. This dimensional enhancement increases the effective surface area and creepage distance, providing additional paths that suppress leakage current between external electrodes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250308731A1Ceramic component and method for manufacturing ceramic component

Publication Date: 2025.10.02 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A ceramic component is excellent in leakage current suppression property, plating flow suppression property, and moisture resistance, and has improved electrode fixing strength. The ceramic component includes a ceramic body, an internal electrode disposed inside the ceramic body, an insulation layer covering a surface of the ceramic body, and an external electrode covering a part of a surface of the insulation layer and electrically connected to the internal electrode. The insulation layer includes a flat portion and a plurality of projections.