Multilayer Ceramic Side Sheet Bonding Without Air Voids

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for manufacturing multilayer ceramic components face issues with air trapping between the cut side surfaces and the side green sheets, leading to voids that can degrade insulation and reliability, and require costly adhesive sheets and complex processing for attaching the side green sheets.

Innovation Solution

A method involving cutting a multilayer base with exposed internal electrode layers, applying an air remover to the cut side surfaces, and attaching a side green sheet while using a jet stream of dry ice microparticles to remove excess sheet material, ensuring air-free attachment and efficient processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive sheets and complex processing are used to attach side green sheets, then the attachment reliability is improved, but the manufacturing cost and process complexity increase

Engineering Contradiction:

Improveattachment reliabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts and removes the harmful element (air) from the interface between the cut side surface and the side green sheet by applying an air remover. This eliminates the need for adhesive sheets and complex processing while ensuring reliable attachment, as the air-free interface allows direct bonding without trapped air pockets that would compromise reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The air remover acts as an intermediary substance applied to the cut side surface before attaching the side green sheet. It facilitates direct bonding by preventing air entrapment, replacing the need for adhesive sheets while maintaining attachment reliability through a clean, air-free interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If adhesive sheets are used to attach side green sheets, then the attachment reliability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveattachment reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention extracts and removes the harmful element (air) from the interface between the cut side surface and the side green sheet by applying an air remover. This eliminates the need for expensive adhesive sheets while ensuring reliable attachment, as the air-free interface allows direct bonding without trapped air pockets that would compromise reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The air remover is a inexpensive, consumable substance applied temporarily to the cut side surface during the attachment process. It performs its function of preventing air entrapment and is then removed or evaporated, replacing the need for costly adhesive sheets while maintaining attachment reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If air is trapped between cut side surfaces and side green sheets, then the processing is simpler, but the insulation and reliability deteriorate due to voids

Engineering Contradiction:

Improveprocessing simplicityVSAvoidinsulation reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention applies an air remover to the cut side surface before attaching the side green sheet to prevent air entrapment in advance. This preliminary action eliminates air pockets that would otherwise form voids and compromise insulation reliability, ensuring a sound bond between the components.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The invention converts the potentially harmful effect of air entrapment into a beneficial process by using the air remover to actively eliminate air from the interface. The air remover facilitates the removal of harmful air pockets, ensuring void-free bonding that maintains both processing simplicity and insulation reliability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 method prevents air trapping, reduces voids, and enhances the reliability and insulation of multilayer ceramic components by ensuring a void-free interface between the cut side surfaces and the side green sheets, while also simplifying the processing and reducing component costs.

Implementation Method 1

removing a portion of the side green sheet other than a portion pressed against the cut side surface with a jet stream including dry ice microparticles

Methodology Applied

Scientific EffectSublimation: Sublimation

Data Source

PatentUS20240351325A1Method for manufacturing multilayer ceramic electronic components

Publication Date: 2024.10.24 KYOCERA CORP

AI summary

A method includes cutting a multilayer base including a plurality of dielectric ceramic bodies and a plurality of internal electrode layers alternately stacked on one another along a cutting line orthogonal to the multilayer base to obtain a plurality of base precursors each including a cut side surface on which the plurality of internal electrode layers is exposed, aligning the plurality of base precursors each to have the cut side surface being opened, applying an air remover to the cut side surface being opened, and placing a side green sheet into contact with the air remover applied to the cut side surface and pressing the side green sheet.