Optimization of Mlcc Bar Design to Minimize Failure Rates Under Warm Isostatic Pressing Using Numerical Analysis and Homogenization Method

Abstract

Multilayer ceramic capacitors (MLCCs) are essential electronic components constructed with alternating layers of electrode and dielectric materials. The manufacturing process of MLCCs utilizes Warm Isostatic Pressing (WIP) to laminate these layers into an MLCC bar. However, due to the heterogenous multilayered structure of the bar, non-uniform deformation occurs after the procedure. This study aims to address the issue by optimizing the design of MLCC bar to minimize non-uniform deformation and reduce subsequent failure rates of MLCC production under WIP condition. Finite element analysis serves as the primary research tool, and a homogenization method is employed to simplify the geometry of the bar while maintaining accurate results of analysis. The findings suggest that the index region design of the bar has a significant effect on the deformation pattern and failure rates. Specifically, the stiffness of the side and corner index regions impacts the curvature observed at the sides of the bar. Through sensitivity studies on the corner and side index regions, the study successfully optimizes the MLCC bar design, potentially reducing the failure rate of MLCC production to zero.

Keywords: Homogenization, MLCC, MLCC bar, Finite Element Analysis, design optimization, Warm Isostatic Pressing