Multi-layer Ceramic Capacitor Shrinkage Mismatch Prevention

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Solution Overview

Problem

The existing method of providing side margins to multi-layer ceramic capacitors in a later step leads to peeling issues during sintering, causing insulation failures due to moisture ingress and mismatched shrinkage behaviors between the functional unit and covers.

Innovation Solution

A multi-layer ceramic electronic component configuration where the covers have a high stiffness, sandwiching the functional unit, ensuring a shrinkage behavior match and preventing side margin peeling, with a relationship of (2*t2)/t1≥0.6, where t1 is the functional unit dimension and t2 is the cover dimension, to maintain structural integrity and prevent insulation failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If side margins are provided to multi-layer units in a later step, then variations in capacitance can be kept small, but the side margins are easily peeled from the side surfaces during sintering

Engineering Contradiction:

Improvecapacitance variationVSAvoidside margin peeling

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies preliminary action by providing side margins to the multi-layer units before the sintering process, rather than in a later step. This allows the side margins to be properly integrated with the multi-layer unit structure during sintering, preventing peeling while maintaining manufacturing precision. The side margins are formed on the multi-layer units at a stage where they can be effectively bonded before final sintering completes the structural integration.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If side margins are provided in a later step, then internal electrode positioning accuracy is improved, but moisture can enter the side surfaces causing insulation failure

Engineering Contradiction:

Improveinternal electrode positioningVSAvoidmoisture ingress

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by providing side margins before sintering, which creates a complete protective barrier around the multi-layer unit. This preliminary provision of side margins ensures that the side surfaces are covered before the sintering process, preventing moisture from entering and causing insulation failure, while still maintaining the internal electrode positioning accuracy benefit.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If the functional unit shrinks differently from the covers during sintering, then the multi-layer unit can accommodate dimensional changes, but the side margin peels from the side surface

Engineering Contradiction:

Improvedimensional adaptabilityVSAvoidside margin adhesion

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent applies preliminary action by providing side margins before sintering, which allows the side margins to be integrated with both the functional unit and covers during the sintering process. This preliminary provision ensures that even when differential shrinkage occurs between the functional unit and covers, the side margins remain adhered to the side surfaces, preventing peeling while maintaining dimensional adaptability.

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

This configuration effectively prevents side margin peeling and insulation failures, ensuring high reliability and small variations in capacitance by mitigating shrinkage mismatch and maintaining structural integrity during sintering.

Implementation Method 1

the covers that sandwich the functional unit therebetween and have a high stiffness hinder the functional unit from shrinking in a behavior different from the behavior of the covers

Methodology Applied

Scientific EffectMechanical constraint: Mechanical Force

Implementation Method 2

the multi-layer unit during sintering has different shrinkage behaviors between the functional unit including the internal electrodes and the cover including no internal electrodes

Methodology Applied

Scientific EffectSintering shrinkage: Sintering

Data Source

PatentUS11694845B2Multi-layer ceramic electronic component and method of producing the same

Publication Date: 2023.07.04 TAIYO YUDEN KK

AI summary

A multi-layer ceramic electronic component includes a multi-layer unit and a side margin. The multi-layer unit includes a functional unit including internal electrodes laminated in a first direction, and a pair of covers that covers the functional unit from both sides in the first direction, the multi-layer unit satisfying a relationship of (2*t2)/t1≥0.6, where t1 represents a dimension of the functional unit in the first direction and t2 represents a dimension of each of the pair of covers in the first direction. The side margin covers the multi-layer unit in a second direction orthogonal to the first direction.