Method of forming an electrode in a ceramic transducer electronic component

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Solution Overview

Problem

Existing methods for forming electrodes in ceramic transducer electronic components require expensive silver materials or specialized heat treatment processes, limiting cost-effectiveness and efficiency.

Innovation Solution

A method involving laser patterning and electroless plating is used to form electrodes on a ceramic transducer, optimizing laser power and speed conditions to achieve uniform patterning and adhesion, using a PZT-PZN piezoelectric ceramic composition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silver material is used for electrode formation, then electrode performance is improved, but material cost increases

Engineering Contradiction:

Improveelectrode performanceVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent replaces expensive silver electrodes with copper electrodes that can be formed through electroless plating on laser-patterned ceramic surfaces. The copper material is significantly cheaper than silver while achieving comparable electrode performance through the controlled plating process and optimized laser parameters.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent optimizes laser processing parameters (power, speed, wavelength) to create surface patterns that enable effective copper electroless plating. By adjusting these parameters, the surface roughness and catalytic activity are controlled to achieve uniform copper electrode deposition with good adhesion, matching silver electrode performance.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If copper material is used for electrode formation, then material cost is reduced, but special heat treatment process is required

Engineering Contradiction:

Improvematerial costVSAvoidheat treatment process

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent performs laser patterning before electroless plating to create surface patterns that serve as nucleation sites for copper deposition. This preliminary surface modification eliminates the need for subsequent heat treatment processes, as the laser-patterned surface provides sufficient catalytic activity for direct copper plating at lower temperatures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional thermal processing with laser-based patterning. The laser creates surface patterns through ablation and melting without requiring high-temperature heat treatment, thus simplifying the overall process and avoiding the complexity of controlled atmosphere heat treatment that would be needed for copper electrodes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If laser processing parameters are not optimized, then processing time is reduced, but patterning quality and electrode adhesion deteriorate

Engineering Contradiction:

Improveprocessing speedVSAvoidpatterning quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent establishes dynamic relationships between laser power, processing speed, and surface roughness. By optimizing these parameters together (power: 10-50W, speed: 100-400mm/s, wavelength: 1064nm), the process achieves both high productivity and high patterning quality, with surface roughness values of 2-5μm that ensure excellent copper electrode adhesion.

Inventive Principle:

Principle #15Dynamics

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 approach reduces costs while maintaining or improving piezoelectric performance, achieving electrode adhesion comparable to silver electrodes through controlled laser processing and electroless plating.

Implementation Method 1

irradiating a laser on a surface of the sintered body for a ceramic transducer to perform patterning

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

performing an electroless plating process on or over the sintered body for a ceramic transducer, on which the patterning is formed, to form a metal electrode

Methodology Applied

Scientific EffectElectroless plating: Electroplating

Data Source

PatentUS12402534B2Method of forming an electrode in a ceramic transducer electronic component

Publication Date: 2025.08.26 KOREA ELECTRONICS TECH INST

AI summary

A method of forming an electrode in a ceramic transducer electronic component is provided. The method includes preparing a sintered body for a ceramic transducer containing a metal oxide, performing patterning by irradiating a laser on a surface of the sintered body for a ceramic transducer, and forming a metal electrode by performing an electroless plating process on the sintered body for a ceramic transducer on which the patterning is formed, wherein, in the performing of the patterning by irradiating the laser on the surface of the sintered body for a ceramic transducer, the patterning is performed by irradiating the laser that satisfies at least one of a predetermined power condition and a predetermined processing speed condition.