Ceramic Substrate Division via Pressed End Surface Junctions
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Solution Overview
Problem
Existing methods for producing ceramic substrates and module components struggle with efficiently creating end surfaces perpendicular to the mother substrate during division, often resulting in angled surfaces and poor production efficiency.
Innovation Solution
A method involving cutting an unfired mother ceramic substrate at a predetermined position, pressing to join cross-sectional end surfaces, firing to strengthen the junction, and then dividing along the end surface junction to produce ceramic substrates or module components with perpendicular end surfaces, allowing for high form accuracy and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If notches are formed in one surface of a mother substrate to enable breaking into separate substrates, then the substrate can be divided, but the end surfaces become angled instead of perpendicular to the surface
Solution Approach 1:
The patent applies preliminary action by forming notches on both upper and lower surfaces of the mother substrate before the breaking operation. These pre-formed notches serve as guides that ensure the break occurs at the correct position and produces perpendicular end surfaces, rather than angled surfaces as in conventional single-surface notching methods.
2Manufacturing precision
If notches are formed in each mother substrate individually, then the division can be controlled, but the production efficiency decreases
Solution Approach 1:
The patent merges multiple operations into a single process by stacking multiple mother substrates together and forming notches on all substrates simultaneously through one notching operation. This combining approach maintains precise control over division positions while dramatically improving production efficiency compared to individual notching of each substrate.
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 ensures the production of ceramic substrates and module components with end surfaces perpendicular to the mother substrate, enhancing production efficiency and form accuracy, and can include multilayer structures and conductor patterns.
Implementation Method 1
a firing step in which the unfired mother ceramic substrate including an end surface junction, an area resulting from joining the cross-sectional end surfaces, is fired
Data Source
AI summary
In a method for manufacturing ceramic substrates and module components, an unfired mother ceramic substrate is cut at predetermined positions for division into separate unfired ceramic substrates. The cut unfired mother ceramic substrate is pressed such that pressure is applied parallel or substantially parallel to its main surfaces so that the cross-sectional end surfaces created in the cutting step are joined. The unfired mother ceramic substrate including end surface junctions, resulting from joining of the cross-sectional end surfaces, is fired. The fired mother ceramic substrate is broken along the end surface junctions to divide it into separate ceramic substrates.