Multilayer Ceramic Capacitor Electrode Grouping for Lamination Defects
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Solution Overview
Problem
The productivity of multilayer ceramic capacitors is significantly reduced due to defects occurring during the lamination of a large number of dielectric green sheets, requiring the re-lamination of thousands of sheets if a single defect is found.
Innovation Solution
The internal electrode layers are divided into groups with controlled deviations in width and length directions, allowing for independent replacement of defective blocks, thereby improving productivity by minimizing the need to re-laminate entire sets of dielectric green sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of dielectric green sheets (1,000 or more) are laminated at a time to increase capacitance, then the capacitance of the multilayer ceramic capacitor is improved, but the productivity is significantly reduced because any single defect requires re-lamination of the entire set
Solution Approach 1:
The internal electrode layers are divided into M groups, where each group independently includes N internal electrode layers continuously in the lamination direction. This segmentation allows defective groups to be identified and replaced individually, rather than requiring re-lamination of the entire 1,000+ sheet stack. The groups are structured with controlled deviations in width and length directions to ensure proper alignment while enabling modular replacement.
2Quantity of substance
If 1,000 or more dielectric green sheets are laminated at a time to achieve high capacitance, then the capacitance increases, but the complexity of the lamination process and defect management increases
Solution Approach 1:
The internal electrode layers are divided into M groups, where each group independently includes N internal electrode layers continuously in the lamination direction. This segmentation allows defective groups to be identified and replaced individually, rather than requiring re-lamination of the entire 1,000+ sheet stack. The groups are structured with controlled deviations in width and length directions to ensure proper alignment while enabling modular replacement.
Data Source
AI summary
A multilayer ceramic capacitor includes a laminate including dielectric layers and internal electrode layers, first and second main surfaces, first and second side surfaces, and first and second end surfaces, and external electrodes covering the first and second end surfaces, respectively, and connected to the internal electrode layers. The internal electrode layers are divided into M groups each including N internal electrode layers. A total number of internal electrode layers included in the first to M-th groups is 1,000 or more. A thickness of the dielectric layer is about 0.8 μm or more. In at least one set of an m-th group and an (m+1)-th group, a deviation amount α1 is less than a deviation amount β1. In the m-th group and the (m+1)-th group, a deviation amount α2 is less than a deviation amount β2.