Multilayer Ceramic Capacitor Side Margin Geometry for Moisture Resistance

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Solution Overview

Problem

Conventional methods for attaching side margin portions to multilayer ceramic capacitors result in damage, leading to reduced moisture resistance reliability due to physical property changes and uneven fracture surfaces, which creates a moisture penetration path.

Innovation Solution

A multilayer electronic component design with strategically positioned side margin portions, where the average distance ratios A1/A2 and B1/B2 are optimized between 1.5 and 2.5, and between 0.35 and 0.55, respectively, to prevent damage during the attachment and punching process, ensuring even coverage and improved reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a sheet for side margin portion is attached and punched using conventional pressing method, then the side margin portion can be formed, but physical properties change due to stretching by heat and volatilization of organic solvent, causing detachment and uneven fracture surface

Engineering Contradiction:
Improveside margin attachment processVSAvoidmoisture resistance reliability
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the temperature parameter during the punching process by introducing a cooling mechanism. The sheet is cooled to a temperature below its glass transition temperature before punching, which prevents stretching and deformation during the process. This parameter change resolves the contradiction by enabling easy manufacturing through punching while maintaining the sheet's physical properties and preventing detachment, thus ensuring moisture resistance reliability.

Inventive Principle:
Principle #35Parameter changes

2Ease of manufacture

If the sheet is stretched by heat during attachment, then the sheet can be formed, but this causes detachment of the sheet and increases processing time

Engineering Contradiction:
Improvesheet forming processVSAvoidprocessing time
Core Design Contradiction:
Ease of manufactureVSLoss of time

Solution Approach 1:

Instead of heating the sheet to make it pliable for attachment, the patent inverts the approach by cooling the sheet to below its glass transition temperature. This makes the sheet rigid and dimensionally stable during punching, eliminating the need for subsequent drying and curing processes. The inversion of temperature application resolves the contradiction by enabling easy sheet formation through cooling rather than heating, significantly reducing processing time.

Inventive Principle:
Principle #13The other way round (Inversion)

3Productivity

If conventional pressing method is used for side margin attachment, then the process can be completed, but uneven fracture surface is created which leads to moisture penetration path

Engineering Contradiction:
Improveattachment process efficiencyVSAvoidfracture surface uniformity
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary cooling action to the sheet before the punching process. By cooling the sheet to below its glass transition temperature in advance, the material becomes rigid and maintains its shape during punching. This preliminary action prevents uneven fracture surfaces and ensures uniform, clean edges. The cooling step is performed before punching, which resolves the contradiction by enabling efficient attachment while achieving high manufacturing precision in the fracture surface uniformity.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS20240355548A1Multilayer electronic component and method of manufacturing the same
Publication Date: 2024.10.24 SAMSUNG ELECTRO MECHANICS CO LTD
  • US20240355548A1 patent drawing
  • US20240355548A1 patent drawing
  • US20240355548A1 patent drawing

AI summary

In an example embodiment of the present disclosure, an average distance in the first direction from the active-cover boundary to an end of the side margin portion in the first direction closest to the active-cover boundary among ends of the side margin portion in the first direction is defined as A1, and an average distance in the third direction from the first body-side margin boundary to an end of the side margin portion in the third direction closest to the first body-side margin boundary among ends of the side margin portion in the third direction is defined as A2, and then, A1/A2 is adjusted.