Porous Ceramic Green Sheet Structure for Laminated Components
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Solution Overview
Problem
The manufacturing of laminated ceramic electronic components faces issues with air bubbles getting trapped between stacked ceramic green sheets, leading to cracking during the firing or transfer process, which undermines the reliability of the components.
Innovation Solution
A ceramic green sheet structure comprising a ceramic material and a resin with a porosity of 17% or greater, and a conductive layer formed on the sheet, where the electrode non-formed areas have a porosity of 17% or more and the electrode formed areas have a lower porosity, allowing air bubbles to escape and preventing trapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple ceramic green sheets are stacked to form a laminated structure, then the component achieves its required layered configuration and functionality, but air bubbles become trapped between the sheets causing cracking during firing or transfer processes
Solution Approach 1:
The patent applies porous materials by intentionally creating porous regions in the ceramic green sheet, specifically in the electrode non-formed areas. These porous regions act as air bubble escape channels during the stacking and firing processes. The porosity is controlled to be 10-30% in electrode non-formed areas, providing pathways for trapped air to escape without compromising the overall structural integrity of the laminated component.
Solution Approach 2:
The patent implements local quality by creating non-uniform porosity distribution within the ceramic green sheet. The electrode formed areas maintain low porosity (0-10%) for structural strength, while electrode non-formed areas have high porosity (10-30%) to facilitate air bubble escape. This localized differentiation of material properties resolves the contradiction by allowing the same material to serve dual functions: structural integrity where needed and air release where beneficial.
2Reliability
If the ceramic green sheet has high porosity to allow air bubble escape, then air trapping is eliminated, but the structural strength and integrity of the green sheet may be compromised
Solution Approach 1:
The patent implements local quality by creating non-uniform porosity distribution within the ceramic green sheet. The electrode formed areas maintain low porosity (0-10%) for structural strength, while electrode non-formed areas have high porosity (10-30%) to facilitate air bubble escape. This localized differentiation of material properties resolves the contradiction by allowing the same material to serve dual functions: structural integrity where needed and air release where beneficial.
Solution Approach 2:
The patent applies segmentation by dividing the ceramic green sheet into functionally distinct regions: electrode formed areas and electrode non-formed areas. Each segment serves a specific purpose - the electrode formed areas provide structural framework and electrical functionality, while the electrode non-formed porous regions provide air bubble escape pathways. This segmentation allows the overall structure to achieve both strength and air release capabilities.
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 approach effectively eliminates the trapping of air bubbles between sheets, reducing the likelihood of cracking and ensuring the integrity of the laminated ceramic components during the firing process.
Implementation Method 1
an electrode non-formed area where no conductive layer is formed has a porosity equal to or greater than 17%
Data Source
AI summary
A ceramic green sheet structure has a ceramic green sheet including at least a ceramic material and a resin and a conductive layer formed on the ceramic green sheet. An electrode non-formed area has a porosity equal to or greater than 17%, and preferably, equal to or less than 25%. Moreover, an electrode formed area where the conductive layer is formed may have a smaller porosity than the electrode non-formed area where no conductive layer is formed.