Multilayer Ceramic Capacitor Trimming for Uniform External Electrodes
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Solution Overview
Problem
The deformation of the sintered ceramic body in multilayer ceramic capacitors due to differing shrinkage rates of dielectric and internal electrodes leads to increased short circuit defects and non-optimal capacitance formation during mounting on substrates.
Innovation Solution
A method involving the formation of a ceramic laminate with internal electrodes, followed by sintering to create a trapezoidal-shaped ceramic body, trimming of the deformed surfaces, and applying external electrodes uniformly on trimmed surfaces using laser processing to ensure consistent electrode formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintering is performed to form the ceramic body, then the ceramic laminate is transformed into a dense ceramic structure with internal electrodes, but the ceramic body deforms due to differential shrinkage between dielectric and internal electrode materials
Solution Approach 1:
The patent applies preliminary action by forming a compensation structure on the internal electrode before sintering. This compensation structure is designed to shrink at a different rate than the dielectric layer during sintering, pre-compensating for the dimensional changes that will occur. By preparing this compensation mechanism in advance, the final ceramic body achieves better dimensional accuracy and reduces deformation, thereby preventing short circuit defects while maintaining manufacturing feasibility
Solution Approach 2:
The patent utilizes parameter changes by controlling the shrinkage characteristics of the compensation structure through material composition and geometric design. The compensation structure is engineered with specific material properties and dimensional parameters that allow it to shrink at a controlled rate during sintering, counterbalancing the shrinkage of the dielectric layer. This parameter optimization enables the ceramic body to maintain its shape and dimensions, reducing deformation and improving reliability
2Ease of manufacture
If external electrodes are formed on the deformed ceramic body surface, then the multilayer ceramic capacitor can be completed, but the electrode formation becomes non-uniform leading to poor mounting performance
Solution Approach 1:
The patent applies preliminary action by creating a compensation structure that pre-adjusts the surface geometry before external electrode formation. This compensation structure maintains the surface uniformity needed for consistent electrode deposition, ensuring that external electrodes can be formed uniformly even after sintering-induced shrinkage. The preliminary compensation enables subsequent manufacturing steps to proceed with high precision
Solution Approach 2:
The patent utilizes parameter changes by optimizing the compensation structure's material and geometric parameters to control surface deformation. By adjusting the shrinkage characteristics of the compensation structure, the patent ensures that the external surface maintains uniform dimensions after sintering, providing a consistent substrate for external electrode formation and improving overall manufacturing precision
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
Reduces short circuit defects and enhances capacitance by ensuring uniform electrode formation and improved reliability of multilayer ceramic components.
Implementation Method 1
an operation of sintering the ceramic laminate to form a ceramic body
Implementation Method 2
forming a ceramic body including a dielectric layer and a plurality of internal electrodes by sintering the ceramic laminate
Data Source
AI summary
A method for manufacturing a multilayer ceramic electronic component, includes: an operation of forming a conductive paste for internal electrodes on a ceramic green sheet; an operation of forming a ceramic laminate by laminating a plurality of the ceramic green sheets; an operation of forming a ceramic body including a dielectric layer and a plurality of internal electrodes by sintering the ceramic laminate; an operation of trimming at least one surface of the ceramic body; and an operation of forming at least one external electrode on the at least one trimmed surface of the ceramic body.