Selective Coating of Electronic Components Without Electrode Fouling
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Solution Overview
Problem
Existing methods for selectively coating electronic components are complex and inefficient, often resulting in low productivity and quality issues, particularly when attempting to coat specific areas without adhering to electrodes, which can compromise conductivity.
Innovation Solution
A method involving the application of a surface modifier on selected areas followed by a coating material, using techniques such as masking, surface layer removal, and graft polymerization to ensure precise coating of ceramic or glass components while avoiding metal electrodes, utilizing agents like silane coupling agents and catalyst-containing monomer solutions to achieve selective coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entire surface of an element body is coated with a coating material, then the coating process is simple and productivity is high, but the coating material adheres to electrodes which decreases conductivity
Solution Approach 1:
The patent applies a surface modifier selectively to specific areas of the element body using a mask, creating different surface properties in different regions. The mask covers electrode areas to prevent modifier application, while exposing ceramic areas for modifier application,从而实现局部差异化处理
Solution Approach 2:
The patent introduces a surface modifier as an intermediary substance between the coating material and the element body surface. This modifier selectively enhances coating adhesion on ceramic surfaces while being absent from electrode surfaces, preventing unwanted coating adhesion to electrodes
2Reliability
If selective coating is attempted by conventional methods such as sandblasting or screen printing, then electrode adhesion can be avoided, but the manufacturing process becomes complex and productivity decreases
Solution Approach 1:
The patent applies the surface modifier to the element body surface before the actual coating process. This preliminary modification of the surface properties enables subsequent complete immersion coating while maintaining selectivity, eliminating the need for complex post-coating processing steps
Solution Approach 2:
The mask serves multiple functions: it protects electrode areas from modifier application, defines the pattern for selective coating, and enables simple complete immersion coating methodology. This single tool achieves what would otherwise require multiple specialized processing steps
3Manufacturing precision
If selective coating is attempted by conventional methods, then coating precision can be achieved, but the number of manufacturing steps increases and productivity is reduced
Solution Approach 1:
The patent combines the surface modification step and the coating step into a unified process sequence. By applying the modifier first and then performing complete immersion coating, the method merges what would otherwise be separate selective coating operations into a streamlined two-step process
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 comprehensive and high-productivity selective coating of electronic components, enhancing insulation, moisture resistance, and mechanical strength while maintaining electrode conductivity, suitable for mass production.
Implementation Method 1
applying a surface modifier only on the surface of the selected surface material
Implementation Method 2
coating the surface of the selected surface material to which the surface modifier has been applied with the coating material
Implementation Method 3
producing a polymer resin by graft polymerization from the functional group as a polymerization starting point, to coat only the surface of the selected surface material with the coating material
Data Source
AI summary
An element body has an exposed surface including a selective surface material which is to be coated with the coating material and a non-selected surface material which is not to be coated with the coating material. The selected surface material has different material properties than the non-selected surface material. The element body is coated with the coating material by applying a surface modifier only on the surface of the selected surface material and thereafter coating the surface of the selected surface material to which the surface modifier has been applied with the coating material.