Quartz Vibrator Bonding via Ceramic Plate Inversion

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Solution Overview

Problem

Existing methods for manufacturing quartz vibrators face challenges in achieving high frequency precision due to difficulties in forming precise bonding materials on narrow surfaces, leading to variations in frequency characteristics.

Innovation Solution

A method involving a metallic bonding material with an Au/Sn alloy is applied to a ceramic plate, where the cap is bonded to the plate with a metallic layer on its surface, allowing the bonding material to extend onto side surfaces for improved bonding and reduced variations, using techniques like metallic paste application or plating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If metallic paste printing or plating is used to form bonding material on the narrow end surface of the cap, then bonding precision can be improved, but it becomes difficult to form the bonding material with high precision due to the extremely narrow surface area

Engineering Contradiction:

Improvebonding material precisionVSAvoidbonding material formation difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Instead of disposing bonding material on the narrow end surface of the cap (original approach), the invention inverts the approach by disposing the bonding material on the broader main surface of the ceramic plate. This reversal of the bonding interface location allows for much easier and more precise material application while achieving the same bonding function between the cap and substrate.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces the ceramic plate as an intermediary element with a broader surface area. The bonding material is applied on this intermediary surface rather than directly on the narrow cap end surface, facilitating easier and more precise bonding material formation while maintaining the structural integrity of the assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the bonding material is disposed on the narrow end surface of the cap, then the bonding area is minimized, but it becomes difficult to achieve high frequency precision due to manufacturing variations

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidfrequency precision

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The invention reverses the bonding interface location from the narrow cap end surface to the broader ceramic plate main surface. This inversion enables better control over bonding material disposition, reducing manufacturing variations that would otherwise affect frequency precision while maintaining manufacturing efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention applies bonding material with controlled local distribution on the ceramic plate surface. By disposing the bonding material on the broader plate surface rather than the narrow cap surface, the bonding can be precisely controlled in terms of area, thickness, and distribution, thereby reducing variations that affect frequency precision.

Inventive Principle:

Principle #3Local quality

3Device complexity

If the cap is bonded directly to the ceramic plate without a metallic layer on the cap surface, then the manufacturing process is simplified, but the wettability and bonding strength are reduced

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidbonding strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The invention applies a metallic layer (such as Au, Ag, or Cu) on the bonding surface of the cap as a composite material solution. This metallic coating creates a chemically active surface that enhances wettability with the bonding material (e.g., Au/Sn alloy), significantly improving bonding strength while adding minimal complexity to the manufacturing process.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the surface property parameter of the cap by coating it with a metallic layer. This parameter change (from non-metallized to metallized surface) dramatically improves the chemical reactivity and wettability with the bonding material, thereby enhancing bonding strength without substantially increasing manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

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 enables the production of quartz vibrators with enhanced frequency precision by reducing manufacturing variations and improving the seal of the quartz vibrating element, minimizing the impact of external disturbances.

Implementation Method 1

melting the bonding material, and then allowing the bonding material to set

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

wettability of the metallic layer with respect to the melted bonding material is higher than wettability of the cap main body with respect to the melted bonding material

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS9985599B2Quartz vibrator manufacturing method and quartz vibrator

Publication Date: 2018.05.29 MURATA MFG CO LTD

AI summary

A method capable of manufacturing a quartz vibrator by disposing a metallic bonding material on one main surface of a ceramic plate having a quartz vibrating element mounted thereon. Thereafter, the bonding of a cap having a recess to the ceramic plate by disposing the cap on the one main surface of the ceramic plate so that an open side of the recess faces the ceramic plate, melting the bonding material, and then allowing the bonding material to set, is carried out.