Electrode Embedded Ceramic Structure Thickness Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrode embedded ceramic structures face a trade-off between characteristics and durability, with thinner insulating or protective ceramic layers improving device performance but reducing durability, and thicker layers maintaining durability at the cost of reduced performance.
Innovation Solution
The electrode embedded ceramic structure features a second ceramic layer that is thinner than the first, with a thickness ratio between average and minimum thickness of the second ceramic layer not exceeding 15%, and a percentage of voids less than 0.05%, ensuring improved durability without compromising performance by maintaining a uniform thickness and preventing locally thinned areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second ceramic layer is thinned to improve device characteristics, then performance is improved, but durability decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness of the second ceramic layer to fall within a specific range (5-15 μm) and by regulating the thickness uniformity to within ±10% of the average thickness. This quantitative parameter control resolves the contradiction by identifying the optimal thickness range that simultaneously achieves improved device characteristics and maintained durability, rather than using conventional thick layers.
Solution Approach 2:
The patent employs a slurry application method involving liquid or paste-form ceramic materials that are applied and then sintered. The slurry formulation and application process control the final layer thickness and uniformity, enabling precise thickness control (within ±10% of average) that allows thinning while maintaining structural integrity and durability.
2Reliability
If the second ceramic layer is made thinner, then device performance improves, but local thinning causes reduced durability
Solution Approach 1:
The patent uses slurry application methods (liquid or paste form) that inherently provide uniform distribution. The slurry is applied over the electrode layer and sintered to form a uniformly thick protective layer, preventing local thinning. This hydraulic/slurry-based application process ensures thickness uniformity within ±10% of average thickness across the entire surface.
Solution Approach 2:
The patent controls the thickness parameter to within a specific range (5-15 μm) and maintains uniformity within ±10% of the average thickness. This quantitative parameter control ensures that the thin second ceramic layer maintains consistent thickness across the entire device, preventing local weak points that would compromise durability.
Data Source
AI summary
An electrode embedded ceramic structure includes: a first ceramic layer; an electrode layer formed on the first ceramic layer; and a second ceramic layer covering the first ceramic layer and the electrode layer, the second ceramic layer being thinner than the first ceramic layer. In a cross section of the first ceramic layer, the electrode layer, and the second ceramic layer along a laminating direction in this electrode embedded ceramic structure, T1 and T2 satisfy Equation (T2−T1)/T2≤0.15, where T1 denotes a least thickness in the second ceramic layer, and T2 denotes an average thickness of the second ceramic layer.