Multilayer electronic component and method of manufacturing the same

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Solution Overview

Problem

The miniaturization and capacitance increase of multilayer ceramic capacitors face challenges such as short circuits, decreased capacitance, and breakdown voltage due to reduced internal electrode thickness, primarily caused by non-uniform internal electrode connectivity and smoothness.

Innovation Solution

Controlling the area fraction of the region with brightness intensity between 110% and 126% of the average cover portion intensity, ensuring uniform internal electrode connectivity and smoothness, is achieved by optimizing the thickness and patterning of internal electrodes and dielectric layers, and using continuous supply methods for high-speed printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the thickness of internal electrodes is reduced to achieve miniaturization and capacitance increase, then the size of the multilayer ceramic capacitor is reduced and capacitance is increased, but short circuits between internal electrodes occur, capacitance decreases, and breakdown voltage decreases

Engineering Contradiction:

Improvesize of multilayer ceramic capacitorVSAvoidshort circuit between internal electrodes

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent changes the physical and chemical parameters of the internal electrode paste, including its composition, viscosity, and drying characteristics. By adjusting these parameters, the paste forms internal electrodes with controlled thickness and improved surface smoothness, preventing short circuits even at reduced thicknesses while maintaining reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different paste compositions or processing conditions to specific regions of the internal electrodes. This ensures that critical areas have enhanced properties such as improved connectivity and smoothness, while other regions can be optimized for thickness reduction, thereby preventing short circuits locally where they are most likely to occur

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If the thickness of internal electrodes is reduced to achieve miniaturization and capacitance increase, then the size of the multilayer ceramic capacitor is reduced and capacitance is increased, but internal electrode connectivity becomes non-uniform and smoothness deteriorates

Engineering Contradiction:

Improvesize of multilayer ceramic capacitorVSAvoidinternal electrode connectivity uniformity

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent modifies parameters such as paste viscosity, particle size distribution, and organic vehicle composition to ensure uniform spreading and drying of the internal electrode paste. These parameter changes result in consistent electrode thickness and smooth surfaces across all layers, maintaining manufacturing precision despite reduced thickness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs continuous printing processes with optimized drying conditions that ensure uniform formation of internal electrodes throughout the stacking process. This continuous action prevents variations in connectivity and smoothness that would otherwise occur with batch processing or interrupted operations

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If conventional manufacturing methods are used, then manufacturing process is simple, but productivity is low and manufacturing time is long

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent prepares internal electrode paste with pre-optimized composition and properties before the stacking process. This preliminary preparation ensures that the paste can be quickly and uniformly applied during manufacturing, increasing productivity without requiring complex in-process adjustments or additional processing steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical stacking and alignment methods with printing-based techniques for forming internal electrodes. This substitution enables faster, more precise electrode formation with improved uniformity, significantly increasing manufacturing speed while maintaining process simplicity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20240379289A1Multilayer electronic component and method of manufacturing the same

Publication Date: 2024.11.14 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

There is provided a multilayer electronic component in which a short circuit between the internal electrodes, a decrease in capacitance, a decrease in breakdown voltage, and the like, may be suppressed by controlling an area fraction occupied by a region in which an intensity of brightness in a capacitance formation portion is 110% or more and 126% or less of an average value of an intensity of brightness of a cover portion.