Multilayer Ceramic Capacitor Cover Segmentation for Carbon Removal

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Solution Overview

Problem

Multilayer ceramic capacitors face issues with cracks, delamination, and poor withstand voltage characteristics due to residual carbon and carbon content, which hinders achieving high reliability.

Innovation Solution

A multilayer ceramic capacitor design with a cover part comprising active part protective covers and exterior covers, where the exterior covers have a higher porosity and specific material composition to facilitate faster residual carbon removal, and the active part protective covers are adjacent to the active part to enhance protection and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the cover part is designed with exterior covers having higher porosity to facilitate faster residual carbon removal, then the reliability is improved, but the manufacturing complexity increases due to the need for separate preparation of second and third green sheets

Engineering Contradiction:

ImprovereliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cover part is segmented into two distinct components: an active part protective cover (second green sheets) and an exterior cover (third green sheets). This segmentation allows each component to have optimized properties - the exterior cover with higher porosity for carbon removal and the protective cover for structural integrity, resolving the contradiction between reliability improvement and manufacturing complexity by creating specialized sub-components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cover part are assigned different porosity characteristics and material properties. The exterior cover region has higher porosity specifically for carbon removal functionality, while the active part protective cover region maintains lower porosity for protection. This local differentiation enables targeted optimization of each region's properties to meet specific functional requirements.

Inventive Principle:

Principle #3Local quality

2Reliability

If the exterior cover has higher porosity to enable faster carbon removal, then residual carbon content is reduced, but the structural strength may be compromised

Engineering Contradiction:

Improveresidual carbon contentVSAvoidstructural strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The cover part is divided into two functional segments: the exterior cover with high porosity dedicated to carbon removal, and the active part protective cover with lower porosity providing structural strength. This segmentation allows each segment to optimize its porosity for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different porosity levels are applied locally to different regions of the cover part. The exterior cover region maintains high porosity for efficient carbon removal pathways, while the active part protective cover region maintains lower porosity for mechanical strength and structural integrity.

Inventive Principle:

Principle #3Local quality

3Reliability

If separate green sheets are prepared for active part protective cover and exterior cover, then the removal rate of residual carbon is improved, but the manufacturing time increases

Engineering Contradiction:

Improveremoval rate of residual carbonVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The manufacturing process is segmented into separate preparation steps for second green sheets (active part protective cover) and third green sheets (exterior cover). This segmentation enables optimized carbon removal in the exterior cover while maintaining protective functionality, achieving the dual benefit of improved carbon removal rates and functional specialization despite the additional processing step.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second and third green sheets are prepared in advance as separate components before final assembly. This preliminary preparation allows for optimized material properties and porosity characteristics in each component, facilitating more effective carbon removal during sintering while maintaining manufacturing efficiency through pre-planned sequential processing.

Inventive Principle:

Principle #10Preliminary action

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

The design effectively reduces residual carbon content, improves crack resistance, and enhances the reliability of multilayer ceramic capacitors by efficiently removing carbon during the sintering process, thereby improving withstand voltage characteristics.

Implementation Method 1

the exterior covers have a higher porosity and specific material composition to facilitate faster residual carbon removal

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

sintering the green sheet multilayer body

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS9812259B2Multilayer ceramic capacitor, method of manufacturing the same, and board having the same

Publication Date: 2017.11.07 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A multilayer ceramic capacitor may include: an active part including dielectric layers and internal electrodes which are alternately stacked therein; and a cover part disposed on at least one of an upper surface and a lower surface of the active part. The cover part may include an active part protective cover and an exterior cover, and the active part protective cover may be disposed adjacent to the active part.