Piezoelectric Layer Spacing Structure for Thinner Resonators

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Solution Overview

Problem

Existing piezoelectric devices suffer from increased thickness due to variable distance between piezoelectric layers during manufacturing, which can be attributed to the use of a frame-shaped connecting layer made of metal, leading to inconsistent spacing.

Innovation Solution

The implementation of an intermediate layer between piezoelectric layers with strategically placed space portions and through holes, allowing precise control over the distance between layers, thereby reducing the overall thickness of the device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a frame-shaped connecting layer made of metal is used to connect substrates, then the substrates can be connected structurally, but the distance between piezoelectric layers becomes variable during manufacturing, requiring increased substrate distance and leading to increased device thickness

Engineering Contradiction:

Improvesubstrate connectionVSAvoiddevice thickness

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The patent introduces an intermediate layer as a mediator between the first and second piezoelectric layers. This intermediate layer includes space portions that precisely define and maintain a fixed distance between the piezoelectric layers, eliminating the variability caused by frame-shaped connecting layers while preventing direct contact between the piezoelectric layers.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the distance between piezoelectric layers is increased to accommodate manufacturing variability, then manufacturing flexibility is improved, but the overall device thickness increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoiddevice thickness

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

The patent changes the structural parameter of the intermediate layer to include space portions with precisely controlled dimensions. This allows the distance between piezoelectric layers to be fixed at an optimal value that minimizes device thickness while still accommodating manufacturing tolerances through the designed space portions.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If substrates are connected by metal connecting layers, then electrical connection is achieved, but moisture and dust ingress pathways are created, reducing device reliability

Engineering Contradiction:

Improveprotection against moisture and dustVSAvoidmoisture and dust ingress

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The intermediate layer acts as an intermediary barrier between the piezoelectric layers, preventing direct contact and creating a sealed structure with space portions that eliminate pathways for moisture and dust ingress, thereby improving device reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The space portions in the intermediate layer create an isolated, protected environment between the piezoelectric layers, effectively creating an inert barrier that prevents harmful external factors such as moisture and dust from reaching the sensitive piezoelectric components.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 configuration results in a piezoelectric device with a reduced thickness and improved reliability by preventing moisture and dust ingress, while enhancing frequency and resonance characteristics.

Implementation Method 1

a first piezoelectric layer with a thickness in a first direction, the first piezoelectric layer including an upper surface being one surface of the first piezoelectric layer in the first direction, and a lower surface being another surface of the first piezoelectric layer in the first direction

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS20260074670A1Piezoelectric device

Publication Date: 2026.03.12 MURATA MFG CO LTD

AI summary

A piezoelectric device includes a first piezoelectric layer including upper and lower surfaces, a first support on a lower surface side of the first piezoelectric layer, first upper and lower electrodes respectively on the upper and lower surfaces of the first piezoelectric layer at least partially facing each other, a second piezoelectric layer including upper and lower surfaces, a second support on a lower surface side of the second piezoelectric layer, and second upper and lower electrodes respectively on the upper and lower surfaces of the second piezoelectric layer at least partially facing the second upper electrode, and an intermediate layer. The upper surfaces of the first and second piezoelectric layers face each other in a first direction, and the intermediate layer is located between the upper surfaces of the first and second piezoelectric layers.