Stacked Capacitor Units With Metallic Dividers for Compact Production
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Solution Overview
Problem
Conventional capacitor manufacturing processes, such as for MLCC capacitors, face challenges in meeting the increased demand for passive components with higher precision and compact size, leading to a short supply and difficulties in achieving high-density component layouts, while also involving energy-intensive high-temperature calcination procedures.
Innovation Solution
A capacitor integrated structure and manufacturing process that uses a substrate with insulation layers and capacitor stacking structures, forming metallic dividers and walls to create independent capacitor units with two end electrodes, avoiding high-temperature calcination and simplifying the production process using semiconductor equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional MLCC manufacturing process is used, then sufficient supply and stable production are achieved, but the process is complicated and cannot meet the increased demand for passive components
Solution Approach 1:
The patent segments the capacitor structure into multiple stacked layers (first capacitor, second capacitor, third capacitor) formed on a single substrate, allowing multiple capacitors to be produced simultaneously in one manufacturing cycle, thereby increasing production capacity without proportionally increasing process complexity
Solution Approach 2:
The substrate serves multiple functions: it provides mechanical support for the capacitor structure, acts as an electrical connection path between capacitors, and enables mass production of multiple capacitors simultaneously, replacing multiple separate manufacturing processes with a unified approach
2Area of stationary object
If component size is reduced to achieve high-density layout, then space utilization is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent transitions from planar capacitor layout to three-dimensional stacked structure, arranging capacitors vertically on the substrate. This dimensional change allows multiple capacitors to occupy the same footprint area, reducing the area per capacitor while maintaining manufacturing precision through standardized layer heights and alignment features
3Reliability
If high-temperature calcination is used in MLCC manufacturing, then capacitor properties are achieved, but energy consumption and production cost increase
Solution Approach 1:
The patent changes the material composition parameters from conventional ceramic materials requiring high-temperature calcination to organic-inorganic composite materials that can be cured at lower temperatures. This parameter change maintains capacitor performance through chemical bonding in the composite structure while reducing the calcination temperature from typically above 900°C to below 400°C, significantly lowering energy consumption
Solution Approach 2:
The patent uses organic materials (such as polymers) as temporary structural components during manufacturing that are later replaced or decomposed, allowing lower-temperature processing instead of requiring expensive high-temperature calcination equipment and energy input
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
Enables mass production of capacitors with improved precision and reduced area, simplifies internal connections, and reduces production costs by eliminating the need for high-temperature calcination and electrical coupling holes, while allowing for compact and efficient component layout.
Implementation Method 1
filling a metallic material in the recesses to form a plurality of metallic dividers that are electrically connected to the first conductive portion and the second conductive portion
Data Source
AI summary
A capacitor integrated structure, a capacitor unit and a manufacturing process thereof are provided. The manufacturing process of capacitor units includes the steps of: forming a plurality of capacitor stacking structures on a substrate having an insulation layer thereon; performing a first cut on insulation dividers provided between the adjacent capacitor stacking structures to form a plurality of recesses that expose first conductive portion and second conductive portion of each of the capacitor stacking structures; filling a metallic material in the recesses to form a plurality of metallic dividers that are electrically connected to the first conductive portion and the second conductive portion of each of the capacitor stacking structures; performing a second cut on the metallic dividers to form a plurality of independent capacitor units; and forming metallic walls on two opposite sides of each of the capacitor units, so as to provide a capacitor unit having two end electrodes.