Curved Corner Side Margins in Multi-Layer Ceramic Capacitors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing multi-layer ceramic capacitors face challenges in forming uniform side margins, which are crucial for ensuring insulation properties, especially when side margins are made thin, as they often result in inadequate punching and adherence issues during the ceramic green sheet processing.
Innovation Solution
A multi-layer ceramic capacitor design with a side margin configuration that includes a rectangular shape with rounded corners, where the corner portion is curved to satisfy specific ratios, allowing for appropriate shear force distribution during the punching process, ensuring proper formation and preventing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If side margins are made thinner to enlarge internal electrodes, then capacitance increases, but insulation properties of the periphery of the internal electrodes cannot be ensured
Solution Approach 1:
The corner portions of the side surface are formed with a curved shape having a radius of curvature of 10 μm to 60 μm. This curvature distributes the load and generates appropriate shear force during punching, preventing the ceramic green sheet from adhering to surfaces other than the side surface while ensuring proper punching of side margins with uniform thickness, thus maintaining insulation properties even when side margins are thin
2Volume of moving object
If side margins are made thinner to meet miniaturization demands, then device size decreases, but manufacturing precision of side margins deteriorates
Solution Approach 1:
The curved corner portions with specific radius of curvature (10 μm to 60 μm) distribute the punching load evenly, enabling precise formation of uniform side margins even at thin dimensions. This curvature prevents irregular punching and adhesion defects that typically occur with thinner side margins in conventional sharp-cornered designs
3Ease of manufacture
If conventional punching methods are used on green chips with exposed internal electrodes, then side margins can be formed, but the ceramic green sheet adheres to surfaces other than the side surface and punching is insufficient
Solution Approach 1:
The curved corner portions with radius of curvature of 10 μm to 60 μm distribute the punching load and generate appropriate shear force, preventing the ceramic green sheet from adhering to the end surface or main surface during punching. This ensures clean, precise punching of side margins without adhesion defects or insufficient punching
Solution Approach 2:
By controlling the radius of curvature parameter of the corner portions within the specific range of 10 μm to 60 μm, the punching process parameters are optimized to achieve appropriate shear force distribution, preventing adhesion and ensuring complete punching of side margins with uniform thickness
Data Source
AI summary
A multi-layer ceramic capacitor includes: a multi-layer unit including a capacitance forming unit including internal electrodes laminated in a first direction, a drawn portion extending from the capacitance forming unit in a second direction, and a cover that covers the capacitance forming unit and the drawn portion in the first direction, the multi-layer unit having a main surface facing in the first direction, an end surface facing in the second direction, and a side surface facing in a third direction; and a side margin provided to the side surface, the side surface including a first straight portion including an outer edge of the main surface and extending in the second direction, a second straight portion including an outer edge of the end surface and extending in the first direction, and a corner portion that connects the first and second straight portions with each other, the corner portion being curved.