Multi-Layer Ceramic Capacitor Offset Sections for Short Circuit Prevention

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Solution Overview

Problem

Miniaturization of multi-layer ceramic capacitors leads to increased risk of short circuits due to electrode elongation and foreign matter adhesion on cut faces, which existing methods fail to completely prevent.

Innovation Solution

The implementation of offset sections between internal electrodes and side margins, formed through etching before side margin formation, to insulate electrode ends and prevent conductive contact, using techniques like acid etching or laser irradiation to create gap or amorphous areas, ensuring a minimum offset width of 0.1 μm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If the side faces of the multi-layer chips are cut off to expose the internal electrodes, then the intersection areas of the internal electrodes are enlarged, but the cut faces may be scratched or foreign matters may be adhered to the cut faces causing short circuits

Engineering Contradiction:

Improveintersection area of internal electrodesVSAvoidshort circuit prevention

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent applies preliminary action by forming the offset sections that recess the internal electrode ends from the side faces before final assembly. This pre-formed offset structure ensures that even if scratches or foreign matters are present on the side faces during manufacturing, the electrode ends do not make direct contact, thereby preventing short circuits while maintaining enlarged intersection areas.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The offset sections act as an intermediary barrier between the internal electrodes and the side faces. By creating a recessed region with insulating material or air gap, the offset section mediates the potential harmful contact between electrodes and foreign matters on the side faces, preventing direct conductive contact while allowing the electrodes to maintain their functional intersection areas.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the space between the internal electrodes is narrowed for miniaturization, then the capacitor size is reduced, but the elongation of internal electrodes upon cutting increases the risk of short circuits

Engineering Contradiction:

Improvecapacitor sizeVSAvoidelectrode contact prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-forming offset sections that recess the internal electrode ends from the side faces before final assembly. This pre-formed offset structure ensures that even if scratches or foreign matters are present on the side faces during manufacturing, the electrode ends do not make direct contact, thereby preventing short circuits while maintaining enlarged intersection areas.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by creating offset sections only at specific locations where internal electrodes are exposed to side faces, rather than uniformly modifying the entire structure. The offset sections are localized to the critical areas where short circuits could occur, maintaining the overall miniaturized design while providing targeted protection against electrode contact.

Inventive Principle:

Principle #3Local quality

3Area of stationary object

If side margins are formed thinly to enlarge intersection areas, then the capacitor capacity increases, but the protection against scratches and foreign matters on cut faces is reduced

Engineering Contradiction:

Improveintersection area of internal electrodesVSAvoidscratches and foreign matters on side faces

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies segmentation by dividing the side margin structure into two functional zones: the main side margin area that provides insulation and the offset section that specifically addresses the electrode end protection. This segmentation allows the side margins to be formed thinly for capacity enhancement while the offset sections provide targeted protection against harmful factors at the critical electrode locations.

Inventive Principle:

Principle #1Segmentation

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 configuration effectively suppresses short circuits by insulating electrode ends and preventing conductive contact, even with scratches or deposits on the side faces, thereby enhancing the reliability and voltage withstand of the capacitors.

Implementation Method 1

formed through etching before side margin formation

Methodology Applied

Scientific EffectEtching:

Implementation Method 2

using techniques like acid etching or laser irradiation to create gap or amorphous areas

Methodology Applied

Scientific EffectLaser irradiation: Laser

Data Source

PatentUS11017949B2Multi-layer ceramic capacitor and method of producing the same

Publication Date: 2021.05.25 TAIYO YUDEN KK

AI summary

A multi-layer ceramic capacitor according to an embodiment of the present invention includes a multi-layer, side margins and offset sections. The multi-layer includes internal electrodes and dielectric layers alternately laminated. The side margins are configured of a dielectric and disposed to cover side faces of the multi-layer. The offset sections are made with amorphous areas or gap areas. The offset sections are formed between the internal electrodes and the side margins such that ends at side faces of the internal electrodes are offset from the side faces to an inward direction of the multi-layer.