Multilayer Ceramic Component Swelling Prevention via Binder-Plasticizer Ratio
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Solution Overview
Problem
The reduction in size and thickness of electronic components leads to issues with swelling or distortion of multilayer ceramic components due to solvent penetration from conductive pastes during the manufacturing process.
Innovation Solution
A method involving the lamination of ceramic green sheets with specific organic binder and plasticizer ratios to form a green ceramic element body, where the second ceramic green sheets with higher polymerization degree and plasticizer content are used on main surfaces to prevent solvent penetration, and the application of conductive paste only on these surfaces to form external electrodes, followed by firing to create a multilayer ceramic electronic component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conductive paste is applied to the surface of the green ceramic element body, then external electrodes can be formed, but solvent penetration causes swelling or distortion of the green ceramic element body
Solution Approach 1:
The patent applies a preventive coating to the green ceramic element body before applying the conductive paste. This coating is applied in advance to create a barrier that prevents solvent penetration during the subsequent paste application process, thereby preventing swelling or distortion before it occurs.
Solution Approach 2:
The patent introduces a coating layer as an intermediary substance between the green ceramic element body and the conductive paste. This coating layer acts as a mediator that allows the conductive paste to be applied while blocking the harmful solvent from penetrating into the ceramic body, thus resolving the contradiction between forming electrodes and preventing distortion.
2Volume of moving object
If the green ceramic element body is made thinner to reduce component size, then electronic apparatuses can be smaller, but the green ceramic element body becomes more susceptible to swelling or distortion
Solution Approach 1:
The preventive coating is applied to the green ceramic element body before any paste application or processing that could cause distortion. This preliminary protective measure ensures that even thin-walled components maintain their shape integrity throughout the manufacturing process by preventing solvent-induced swelling from the outset.
Solution Approach 2:
The coating layer serves as a protective intermediary that shields the thin green ceramic element body from direct contact with harmful solvents. This mediator allows the manufacturing process to proceed with thin components without compromising their shape stability, as the coating blocks solvent penetration that would otherwise cause swelling.
3Ease of manufacture
If the conductive paste contains solvent for proper application, then the paste can be applied smoothly, but the solvent penetrates into the green ceramic element body causing swelling
Solution Approach 1:
The patent segments the functional components by separating the conductive paste into two distinct layers: a coating layer applied first that serves as a solvent barrier, and then the conductive paste layer applied on top that provides the electrode function. This segmentation allows the solvent-containing paste to be applied smoothly while the underlying coating layer prevents solvent penetration into the ceramic body.
Solution Approach 2:
The coating layer acts as an intermediary barrier between the solvent-containing conductive paste and the green ceramic element body. This mediator enables the paste to maintain its necessary solvent content for smooth application while blocking the solvent from reaching and swelling the ceramic material, thus resolving the contradiction between ease of manufacture and dimensional accuracy.
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 significantly reduces and prevents swelling or distortion of the green ceramic element body, ensuring the integrity and characteristics of the multilayer ceramic electronic component by enhancing bonding and reducing shrinkage differences between layers.
Implementation Method 1
Each of the first and second ceramic green sheets contains an organic binder and a plasticizer. The second ceramic green sheets constituting the main surfaces satisfy 180.56≦A/B wherein A is the polymerization degree of the organic binder, and B is the volume content, in other words, the percentage by volume of the plasticizer.
Data Source
AI summary
A method for manufacturing a multilayer ceramic electronic component significantly reduces and prevents swelling or distortion when a conductive paste is applied to a green ceramic element body. A ceramic green sheet used in the method satisfies 180.56≦A/B wherein A is a polymerization degree of an organic binder contained in the ceramic green sheet, and B is a volume content of a plasticizer contained in the ceramic green sheet.