Elastic Roller Groove Method for Precise Electrode Formation
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Solution Overview
Problem
The existing methods for manufacturing monolithic ceramic capacitors with external electrodes lack precision in shaping, leading to inconsistent electrode formation based on the size of the electrode on the end surface, necessitating a more accurate method for forming external electrodes.
Innovation Solution
A method involving the use of an elastic roller with grooves to apply electroconductive paste onto an electronic component body, ensuring precise alignment and application of the paste across multiple surfaces to form external electrodes with controlled dimensions, and an apparatus that includes a transportation mechanism and heating mechanism to facilitate accurate electrode formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to apply electroconductive paste, then the manufacturing process is simple, but the shape accuracy of external electrodes deteriorates
Solution Approach 1:
An elastic roller with grooves is introduced as an intermediary tool between the paste supply and the electronic component body. The roller receives electroconductive paste and transfers it to the component surface through controlled contact, enabling precise electrode formation without requiring complex direct application mechanisms
Solution Approach 2:
The elastic roller's material properties (elasticity) and geometric parameters (groove depth, width, and pattern) are optimized to control paste transfer. By adjusting these parameters, the paste application precision is improved while maintaining a relatively simple device structure
2Reliability
If the external electrode extends to the end surface, then the electrode connectivity is improved, but the alignment precision deteriorates due to size variation
Solution Approach 1:
The alignment mechanism is replaced from manual or mechanical positioning to a groove-based guiding system. The grooves on the elastic roller physically guide the electrode edges to precise positions, ensuring consistent alignment regardless of electrode size variations
Solution Approach 2:
The grooves are pre-formed on the elastic roller with precise dimensions and positions. This preliminary preparation ensures that when paste is applied, the electrode edges are automatically positioned correctly without requiring real-time adjustment during the application process
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 enables the creation of electronic components with highly accurate external electrode shapes, ensuring consistent and precise electrode formation, which is essential for reliable component mounting and performance.
Implementation Method 1
an elastic roller with grooves to apply electroconductive paste onto an electronic component body
Implementation Method 2
pressing the electronic component body against the outer circumferential surface of the roller
Data Source
AI summary
Electroconductive paste is applied onto an electronic component body to form an external electrode by supplying the electroconductive paste to a first groove on an outer circumferential surface of a roller to extend along a circumference of the roller, disposing the electronic component body such that a second main surface of the electronic component body and an outer circumferential surface of the roller are opposed to each other while a first edge portion defined by the second main surface and a first end surface of the electronic component body is in the first groove when viewed in plan, and pressing the electronic component body against the outer circumferential surface of the roller so that the first edge portion is located in the first groove in a depth direction of the first groove.