Multilayer Ceramic Capacitor Dummy Patterns Warpage
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Solution Overview
Problem
Multilayer ceramic capacitors face warpage issues at the end portions of internal electrodes due to thickness differences, leading to reduced breakdown voltage and reliability, with existing methods like additional dielectric layers or dummy electrode patterns being inefficient and difficult to implement accurately.
Innovation Solution
The introduction of dummy patterns adjacent to internal electrodes, spaced apart and partially overlapping them, to alleviate warpage and improve structural integrity, combined with a method of manufacturing that includes forming these patterns simultaneously with internal electrodes using conductive metal paste on ceramic green sheets, followed by sintering and external electrode connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of dielectric layers is increased to reduce capacitor size, then capacitance density is improved, but warpage of internal electrodes occurs due to thickness differences
Solution Approach 1:
A dummy electrode pattern is introduced as an intermediary element between the internal electrodes and the dielectric layers. This dummy pattern compensates for thickness differences and prevents warpage by providing a reference plane that maintains flatness during the stacking process, allowing high capacitance density to be achieved without electrode deformation.
Solution Approach 2:
The dummy electrode pattern is selectively positioned only in specific regions where thickness differences cause warpage, rather than uniformly across the entire capacitor structure. This localized approach addresses the warpage problem in critical areas while maintaining the overall compact design and high capacitance density.
2Shape
If separate dielectric layers or dummy electrode patterns are printed in margin portions to prevent warpage, then internal electrode flatness is improved, but manufacturing complexity and process time increase
Solution Approach 1:
The dummy electrode pattern is merged with the existing internal electrode structure and printed using the same conductive paste and printing process. This integration eliminates the need for separate manufacturing steps, reducing process complexity while effectively preventing warpage of internal electrodes.
Solution Approach 2:
The dummy electrode pattern serves multiple functions: it prevents warpage of internal electrodes, maintains flatness during stacking, and can be formed using the same printing process as the internal electrodes themselves. This multi-functionality simplifies the overall manufacturing process while achieving the desired structural integrity.
3Reliability
If dummy electrode patterns are printed in margin portions to prevent warpage, then internal electrode stability is improved, but productivity decreases due to additional processes
Solution Approach 1:
The formation of dummy electrode patterns is merged with the existing internal electrode printing process, using the same conductive paste, printing equipment, and firing conditions. This integration allows both structures to be created in a single manufacturing step, maintaining high productivity while improving internal electrode stability.
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 enhances the breakdown voltage and reliability of multilayer ceramic capacitors by reducing warpage and simplifying the manufacturing process, while maintaining high productivity.
Implementation Method 1
preparing a body by compressing, sintering, and cutting the laminate
Data Source
AI summary
A multilayer ceramic capacitor includes: a body including dielectric layers and first and second internal electrodes alternately disposed with respective dielectric layers interposed therebetween; and first and second external electrodes disposed on the body and connected to the first and second internal electrodes, respectively, wherein the body includes first dummy patterns formed adjacent to the first internal electrodes in a width direction to be spaced apart from the first internal electrodes, and the first dummy patterns are stacked to partially overlap the second internal electrodes.