Multilayer Ceramic Capacitor Cladding with Noble Metal
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Solution Overview
Problem
Multilayer ceramic capacitors face limitations in increasing capacitance and maximum voltage while maintaining a given form factor, with traditional manufacturing methods prone to delamination under temperature or pressure stress and restricted to simple flat shapes, leading to reduced performance and potential device failure.
Innovation Solution
The use of 3D printing for additive manufacturing, where ceramic slurry, conductive ink, and ferrite paste are deposited using ink or aerosol jets, allowing for precise and repeatable production of complex shapes with noble metal cladding on base metals to enhance capacitance and voltage without material degradation, and an algorithm to optimize electric field uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional manufacturing methods are used to produce MLCCs, then production process is simple, but delamination occurs under temperature or pressure stress and complex shapes cannot be produced
Solution Approach 1:
The patent transitions from traditional 2D flat layer stacking to 3D printed multilayer structures, enabling complex three-dimensional geometries while maintaining layer integrity through additive manufacturing processes that build structures layer by layer in the third dimension
Solution Approach 2:
The patent changes the manufacturing process parameters from traditional lamination and sintering to 3D printing with controlled deposition, allowing precise control over material placement, layer bonding, and geometric complexity while preventing delamination through optimized printing parameters
2Reliability
If noble metals are used for conductive layers, then temperature tolerance and product life-time are improved, but production cost increases
Solution Approach 1:
The patent applies different material qualities to different regions of the conductive layers, using noble metals only where they provide essential functionality (such as contact areas or high-stress regions) while using base metals in other areas, thereby maintaining reliability while reducing overall material cost
Solution Approach 2:
The patent creates composite conductive structures by combining noble metal particles or layers with base metal matrices, achieving both the temperature tolerance and longevity of noble metals and the cost-effectiveness of base metals through synergistic material combinations
3Quantity of substance
If base metals are used for conductive layers, then production cost is reduced, but chemical reactions with ceramic occur at high temperatures
Solution Approach 1:
The patent introduces noble metal particles or coatings as intermediary layers between base metal conductors and ceramic dielectrics, preventing direct chemical contact and reactions while allowing electrical conductivity to be maintained, thus enabling the use of cost-effective base metals without sacrificing reliability at high temperatures
4Manufacturing precision
If 3D printing is used for additive manufacturing, then geometric precision and material utilization are improved, but manufacturing process complexity increases
Solution Approach 1:
The patent replaces traditional mechanical lamination and alignment processes with 3D printing technology, where digital models and automated deposition systems provide precise geometric control without the mechanical complexity of aligning and bonding multiple separate layers
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 results in higher density components with reduced material waste, increased design flexibility, and improved structural integrity, enabling higher capacitance and voltage ratings within a given form factor while maintaining cost-effectiveness and temperature tolerance.
Implementation Method 1
ink or aerosol jets deposit material such as, e.g., ceramic slurry, conductive ink, ferrite paste, and carbon resistor paste onto a surface
Implementation Method 2
The aforementioned materials can be sintered at high temperatures, and therefore are amenable to integrated manufacture
Data Source
AI summary
Methods and systems to improve a multilayer ceramic capacitor using additive manufacturing are disclosed. Conductive layers and termination caps comprising a base metal may be cladded with a noble metal to lower costs without the tendency of base metal atoms combining with oxygen atoms in the dielectric material as the base metal does not physically contact the dielectric material. The conductive layers may comprise a wavy shape, and may comprise conductive layer ends modified to minimize or eliminate sharp edges and corners, such as comprising a convex, wavy, or bulbous shape. The noble metal portion of a conductive layer may be a minimum thickness required to prevent chemical reactions between the base metal portion and the dielectric material. In conjunction with computer modeling of Laplace's equation, the conductors can be reshaped at little material cost to make the electric field nearly uniform through adjustments of the base metal portion.