Multi-Layer Component Insulation Design

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Solution Overview

Problem

Existing multi-layer components, such as piezo actuators and capacitors, face issues with flashovers on their outer sides due to high electrical field strengths, which can be exacerbated by ceramic passivation leading to limited lifetime and geometrical inaccuracies.

Innovation Solution

A multi-layer component design where the connecting line between adjacent internal electrode layers of unlike polarity on the outer sides is longer than the direct distance between them, eliminating the need for additional passivation and reducing electrical field strength by creating air gaps or dielectric layers that do not extend to the outer sides, thereby preventing flashovers and enhancing performance and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic passivation is applied to prevent flashovers, then reliability is improved, but device complexity and manufacturing complexity increase

Engineering Contradiction:

Improveprevention of flashoversVSAvoidadditional passivation layer

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the ceramic passivation layer entirely and replaces it with an optimized electrode geometry where the connecting line between adjacent internal electrode layers of unlike polarity extends beyond the direct distance, creating a natural insulation effect that prevents flashovers without additional passivation materials

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of adding a passivation layer to prevent flashovers, the patent inverts the approach by designing the electrode connecting line to be longer than the direct distance between electrodes, using the electrode geometry itself to create the insulation effect that would traditionally require a separate passivation layer

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If ceramic passivation is applied to prevent flashovers, then reliability is improved, but manufacturing precision deteriorates due to clamping effects

Engineering Contradiction:

Improveprevention of flashoversVSAvoidgeometrical accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent removes the ceramic passivation layer that causes clamping effects during sintering, thereby eliminating the source of geometrical inaccuracies while maintaining flashover prevention through optimized electrode geometry

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If ceramic passivation is applied to prevent flashovers, then reliability is improved, but the component's lifetime is limited by passivation aging

Engineering Contradiction:

Improveprevention of flashoversVSAvoidcomponent lifetime

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent removes the ceramic passivation layer that is subject to aging, eliminating the lifetime limitation while maintaining flashover prevention through the extended connecting line design between adjacent internal electrode layers of unlike polarity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the aging-prone ceramic passivation with a design that uses the electrode structure itself, which is inherently more stable and does not suffer from the same aging mechanisms that limit the lifetime of organic or ceramic passivation layers

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If ceramic passivation is applied to prevent flashovers, then reliability is improved, but space requirements increase

Engineering Contradiction:

Improveprevention of flashoversVSAvoidspace requirement

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent removes the ceramic passivation layer, thereby reducing the overall volume and space requirements of the multi-layer component while maintaining flashover prevention through the extended connecting line design

Inventive Principle:

Principle #2Taking out (Extraction)

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 design prevents flashovers, extends the component's lifetime, improves performance, reduces space requirements, and achieves higher geometrical accuracy by eliminating the need for ceramic passivation and minimizing clamping effects, while maintaining reliable electrical functionality.

Implementation Method 1

the multi-layer component is a piezo actuator

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

an electrical field strength at a surface of the multi-layer component is reduced. The electrical field strength E is calculated on the basis of the formula E=U/d

Methodology Applied

Scientific EffectElectrical field distribution: Electric Field

Data Source

PatentUS10505099B2Multi-layer component and method for producing a multi-layer component

Publication Date: 2019.12.10 TDK ELECTRONICS AG

AI summary

A multi-layer component having a main body including a stack of alternately arranged dielectric layers and internal electrode layers. In an insulation region on the outer sides of the main body a length of a connecting line between adjacent internal electrode layers of unlike polarity is greater than a direct distance between the adjacent electrode layers. A method for producing a multi-layer component is also provided. The method includes providing a main body including a stack of alternately arranged dielectric layers and internal electrode layers. The method also includes extending the connecting line between adjacent internal electrode layers of unlike polarity on the outer sides of the main body.