Mother Ceramic Substrate Perpendicular Division via Protruding Threads
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Solution Overview
Problem
Existing methods for dividing ceramic substrates often result in oblique or defective end surfaces, making it difficult to achieve perpendicular divisions, which can lead to exposure of inner electrodes and other defects, especially in thin ferrite sheets used for electromagnetic-wave blocking and antenna devices.
Innovation Solution
A mother ceramic substrate is manufactured with dividing grooves on one side and protruding threads on the other, allowing for perpendicular division by concentrating stress on the thread's bottom edge, ensuring accurate and reliable separation of individual substrates with high form accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If dividing grooves are formed only on one side of the mother substrate, then the structure is simple, but the divided end surfaces become oblique and perpendicularity cannot be achieved
Solution Approach 1:
The dividing groove structure is segmented into two parts: a groove on the first surface and a corresponding protruding thread on the second surface. This segmentation allows each feature to perform its function independently - the groove provides the break initiation point while the protruding thread provides the stress concentration point for perpendicular breaking, thereby resolving the contradiction between structural simplicity and perpendicularity achievement.
Solution Approach 2:
The solution transitions from a two-dimensional groove (single surface) to a three-dimensional structure involving both surfaces of the substrate. By adding the protruding thread on the opposite surface, the system utilizes the thickness dimension to create the perpendicular break geometry, achieving precise control over break orientation without excessive complexity.
2Manufacturing precision
If the depth of dividing grooves is increased to prevent oblique break, then perpendicularity improves, but unintentional break during handling occurs
Solution Approach 1:
Instead of uniformly increasing groove depth across the entire structure, the invention applies different features at different locations: a groove on the first surface and a protruding thread on the second surface. This localized approach concentrates stress precisely where needed (at the protruding thread base) to ensure perpendicular breaking, while keeping the overall structure shallow and handling-safe.
Solution Approach 2:
The protruding thread is formed in advance during the same pressing process that creates the dividing groove. This preliminary formation of the stress concentration feature ensures that when breaking occurs, the crack propagates perpendicular to the surfaces without requiring deep grooves, thus preventing handling breakage while ensuring break quality.
3Reliability
If dividing grooves are made shallow to avoid handling break, then reliability improves, but oblique break occurs more frequently
Solution Approach 1:
The protruding thread acts as an intermediary stress concentration feature that mediates between the shallow groove structure and the breaking process. It provides the necessary stress concentration to initiate perpendicular cracks without requiring deep grooves, thus maintaining both handling reliability and break precision simultaneously.
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
The method ensures that divided end surfaces are perpendicular to the principal surfaces, preventing defects like electrode exposure and improving handling reliability, especially for thin ferrite sheets, while allowing for efficient production of ceramic substrates with high form accuracy for various applications.
Implementation Method 1
pressing to be performed on an unfired mother ceramic substrate, thereby forming dividing grooves and protruding threads
Implementation Method 2
concentrating stress on the thread's bottom edge, ensuring accurate and reliable separation
Implementation Method 3
firing the unfired mother ceramic substrate, and thus a mother ceramic substrate which is divided into a plurality of individual substrates along dividing grooves
Data Source
AI summary
Provided is a mother ceramic substrate that, when divided into individual substrates (ceramic substrates), can be divided to cause divided end surfaces to be perpendicular to principal surfaces of the individual substrates, and that can provide ceramic substrates with high form accuracy; an individual ceramic substrate obtained from the mother ceramic substrate; a module component including the ceramic substrate; and a method of manufacturing a mother ceramic substrate. In a mother ceramic substrate that can be divided at a predetermined position and separated into a plurality of individual substrates, a dividing groove that defines a division position is formed in a principal surface on one side, and a protruding thread is formed on a principal surface on another side at a position corresponding to a position of the dividing groove formed in the principal surface on the one side in view in a thickness direction of the mother ceramic substrate.