PATENT DOCUMENT

Publication Number: US-10179254-B2
Application Number: US-201615086813-A
Country: US
Kind Code: B2

Title: Capacitor structure with acoustic noise self-canceling characteristics

Abstract:
This application relates to capacitors that resist deformation because of the configuration of their conductive and dielectric layers. The capacitors are multilayer capacitors that include multiple dielectric and conductive layers. The dielectric layers can be arranged in a way that creates a rigid barrier or dead zone, which can resist mechanical deformation when the multilayer capacitor is charged. In some embodiments, two or more multilayer capacitors are stacked together in an arrangement that causes each of the multilayer capacitors to cancel any deformations of the other when the multilayer capacitors are charged. In this way, noise exhibited by the multilayer capacitors can be reduced.

Claims:
What is claimed is: 
     
       1. A multilayer capacitor, comprising:
 a first plurality of conductive layers, each conductive layer of the first plurality of conductive layers defining a respective first electrode and a respective second electrode, wherein each respective first electrode and each respective second electrode are connected to a first terminal of the multilayer capacitor and wherein each respective first electrode is spaced apart from each respective second electrode; 
 a second plurality of conductive layers, each conductive layer of the second plurality of conductive layers defining a respective third electrode and a respective fourth electrode, wherein each respective third electrode and each respective fourth electrode are connected to a second terminal of the multilayer capacitor and wherein each respective third electrode is spaced apart from each respective fourth electrode; and 
 a plurality of dielectric layers, each respective dielectric layer disposed between a first respective conductive layer from the first plurality of conductive layers and a second respective conductive layer from the second plurality of conductive layers, wherein a portion of each respective dielectric layer is disposed between the first and the second electrodes of the respective first conductive layer and between the third and the fourth electrodes of the respective second conductive layer such that the plurality of dielectric layers form a dielectric barrier that extends through the first and second plurality of conductive layers and from a top of the multilayer capacitor to a bottom of the multilayer capacitor and between each of the first and the second electrodes and each of the third and the fourth electrodes to resist deformation of the multilayer capacitor caused by the multilayer capacitor receiving a charge. 
 
     
     
       2. The multilayer capacitor of  claim 1 , wherein each conductive layer of the first plurality of conductive layers and the second plurality of conductive layers is monolithically bonded to a corresponding adjacent dielectric layers. 
     
     
       3. The multilayer capacitor of  claim 1 , wherein the dielectric barrier is cross shaped. 
     
     
       4. The multilayer capacitor of  claim 1 , wherein each dielectric layer of the plurality of dielectric layers comprises barium or titanium. 
     
     
       5. The multilayer capacitor of  claim 1 , wherein the dielectric barrier comprises a wall that bisects the multilayer capacitor. 
     
     
       6. The multilayer capacitor of  claim 1 , wherein a cross section of the dielectric barrier is defined by an inner edge of at least one conductive layer of the first or second plurality of conductive layers. 
     
     
       7. A method to produce a multilayer capacitor, comprising:
 printing a respective first conductive electrode onto each dielectric layer of a first plurality of dielectric layers, wherein each first conductive electrode is configured to couple a first terminal of the multilayer capacitor; 
 printing a respective second conductive electrode onto each dielectric layer of the first plurality of dielectric layers, wherein each respective second conductive electrode is separated from each respective first conductive electrode, and wherein each second conductive electrode is configured to couple to the first terminal; 
 printing a respective third conductive electrode onto each dielectric layer of a second plurality of dielectric layers, wherein each third conductive electrode is configured to couple a second terminal of the multilayer capacitor; 
 printing a fourth respective conductive electrode onto each dielectric layer of the second plurality of dielectric layers, wherein the fourth conductive electrode is separated from the third conductive electrode, and wherein each fourth conductive electrode is configured to couple to the second terminal; and 
 stacking the first plurality of dielectric layers and the second plurality of dielectric layers to form the multilayer capacitor, wherein the multilayer capacitor comprises a dielectric barrier that extends from a top to a bottom of the multilayer capacitor and between each respective first and second conductive electrodes and each respective third and fourth conductive electrodes, and wherein the dielectric barrier is configured to resist deformation of the multilayer capacitor caused by the multilayer capacitor receiving a charge. 
 
     
     
       8. The method of  claim 7 , wherein the dielectric barrier comprises a cross-shaped barrier, a circular barrier, an oval barrier, or a double cross-shaped barrier. 
     
     
       9. The method of  claim 7 , wherein the dielectric barrier comprises a wall that bisects the multilayer capacitor. 
     
     
       10. The method of  claim 7 , comprising coating a first edge of the multilayer capacitor to form the first terminal and coating a second edge of the multilayer capacitor to form the second terminal. 
     
     
       11. A multilayer ceramic capacitor, comprising:
 a first plurality of ceramic layers, each of the first plurality of ceramic layers having a first conductive portion and a second conductive portion, the first conductive portion being separated from the second conductive portion by a first intermediate ceramic portion of the ceramic layer, and each of the first and second conductive portions having a respective first and second terminal portions; and 
 a second plurality of ceramic layers, each of the second plurality of ceramic layers having a third conductive portion and a fourth conductive portion, the third conductive portion being separated from the fourth conductive portion by a second intermediate ceramic portion of the ceramic layer, and each of the third and fourth conductive portions having a respective first and second terminal portions; and 
 wherein each of the first plurality of ceramic layers is interposed between respective ceramic layers of the second plurality of ceramic layers such that each first intermediate ceramic portions of the first plurality of ceramic layers and each second intermediate ceramic portion of the second plurality of ceramic layers are aligned to form a dielectric barrier that extends from a top to a bottom of the multilayer ceramic capacitor between the respective first and second conductive portions of the first plurality of ceramic layers and between the respective third and fourth conductive portions of the second plurality of ceramic layers, wherein the first and second terminal portions of the first plurality of ceramic layers extend in a first direction, and wherein the first and second terminal portions of the second plurality of ceramic layers extend in a second direction different from the first direction. 
 
     
     
       12. The multilayer ceramic capacitor of  claim 11 , wherein the first conductive portions and the third conductive portions comprise a first capacitor of the multilayer ceramic capacitor, and wherein the second conductive portions and the fourth conductive portions comprise a second ceramic capacitor of the multilayer ceramic capacitor. 
     
     
       13. The multilayer ceramic capacitor of  claim 11 , wherein the dielectric barrier comprises a cross-shape, a circular shape, an oval shape, or a double-cross shape. 
     
     
       14. The multilayer ceramic capacitor of  claim 11 , wherein the ceramic layers of the first and second plurality of ceramic layers comprise barium, or titanium, or any combination thereof. 
     
     
       15. The multilayer ceramic capacitor of  claim 11 , comprising a first terminal configured to electrically couple to the first and second terminal portions of the first plurality of ceramic layers, and a second terminal configured to electrically couple to the first and second terminal portions of the second plurality of ceramic layers.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims the benefit of U.S. Provisional Application No. 62/221,495, entitled “CAPACITOR STRUCTURE WITH ACOUSTIC NOISE SELF-CANCELING CHARACTERISTICS,” filed Sep. 21, 2015, the content of which is incorporated herein by reference in its entirety for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to capacitors. More particularly, the present embodiments relate to multilayer capacitors having layers that are arranged to reduce acoustic noise generated when the multilayer capacitors are operated. 
     BACKGROUND 
     Computing devices incorporate a variety of components that can each occasionally interfere with the operation of other components. Furthermore, some components can interfere with the user experience by, for example, generating audible noise. An example of such components includes capacitors, which can vibrate when a voltage is applied to them. The vibrations can occur at an audible frequency, which can be heard by users of a computing device in which the capacitors are operating. Unfortunately, designing capacitors to effectively provide adequate charge storage without creating audible noise can prove difficult when designing for smaller devices. 
     SUMMARY 
     This paper describes various embodiments that relate to capacitors that have noise canceling properties. In some embodiments, a multilayer capacitor is set forth. The multilayer capacitor can include conductive layers connected to terminals of the multilayer capacitor. Additionally, the multilayer capacitor can include dielectric layers disposed between the conductive layers. A portion of the dielectric layers can form a dielectric barrier that extends through the conductive layers and resists deformation of the multilayer capacitor when the multilayer capacitor is receiving a charge. The conductive layers can be monolithically bonded to the dielectric layers. 
     In other embodiments, a circuit is set forth. The circuit can include a circuit board and a multilayer capacitor connected to the circuit board. The multilayer capacitor can include at least two arrays of conductive electrodes that extend in different directions to resist deformations that can occur when the multilayer capacitor is receiving a charge. The at last two arrays of conductive electrodes include a first conductive electrode having a first surface that faces substantially perpendicular to a second surface of a second conductive electrode. 
     In yet other embodiments, a computing device is set forth. The computing device can include a circuit board and a capacitor connected to the circuit board. The capacitor can include a conductive layer comprising two conductive edges that are across from each other and separated by a dielectric barrier that extends through a portion of the capacitor. A width of separation of the two conductive edges is less than 100 microns, or 60 microns plus or minus 10 microns. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements. 
         FIG. 1A  illustrates a perspective view of conductive electrodes that can be incorporated into a multilayer capacitor according to some embodiments discussed herein. 
         FIG. 1B  illustrates a perspective view of each of the first array of conductive electrodes and the second array of conductive electrodes that can be printed on one or more dielectric layers. 
         FIG. 2  illustrates a perspective view of a multilayer capacitor arranged according to some embodiments discussed herein. 
         FIG. 3A  illustrates a perspective view of conductive electrodes that can be incorporated into a multilayer capacitor according to some embodiments discussed herein. 
         FIG. 3B  illustrates a perspective view of multiple arrays of electrodes printed onto multiple dielectric layers. 
         FIG. 4  illustrates a perspective view of a multilayer capacitor arranged according to some embodiments discussed herein. 
         FIGS. 5A-5B  illustrates a perspective view of conductive electrodes that can be incorporated into a multilayer capacitor to create a dead zone within the multilayer capacitor. 
         FIGS. 6A-6B  illustrate perspective views of a multilayer capacitor with a dead zone to resist deformation of the multilayer capacitor. 
         FIGS. 7A-7B  illustrate perspectives view of a multilayer capacitor that includes a dead zone that extends in at least two directions. 
         FIGS. 8A-8D  illustrate cut away views of various embodiments of the conductive electrodes that can be incorporated into a multilayer capacitor. 
         FIGS. 9A-9C  illustrate cut away views of various embodiments of the conductive electrodes that can be incorporated into a multilayer capacitor. 
         FIG. 10  illustrates an exploded view of an embodiment of a combination of conductive electrodes that can be incorporated into any of the multilayer capacitors discussed herein. 
         FIG. 11  illustrates a method for forming a multilayer capacitor according to any of the embodiments discussed herein. 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The described embodiments relate to capacitors that have self-canceling noise characteristics. Many capacitors exhibit vibrations during operation because of their piezoelectric properties. As a result, capacitors can generate noise within an audible frequency range. When such capacitors are incorporated into certain consumer electronics, the generated noise can be heard by users of the electronics and interfere with the user experience. In order to reduce the amount of noise generated by a capacitor, the capacitors can be designed to cancel out the noise according to the embodiments discussed herein. 
     In some embodiments, a multilayer capacitor is set forth. The multilayer capacitor can include multiple monolithically bonded capacitors separated by one or more dielectric structures. Each of the capacitors within the multilayer capacitor can be arranged to deform in different directions in order to cancel out or counter the deformations of each other. For example, when one of the capacitors within the multilayer capacitor is charged or polarized, the capacitor can experience a deformation in an x-direction, y-direction, and/or z-direction. In order to counter the deformation, another capacitor can be connected to the capacitor to restrict the deformation of the capacitor. The other capacitor can be arranged to deform in an opposite or otherwise different direction than the direction of the deformation of the capacitor. The number of capacitors that can be arranged within the multilayer capacitor can be unlimited depending on the amount of noise to be canceled. For example, in some embodiments, two capacitors are connected within the multilayer capacitor, and in other embodiments, at least three capacitors are connected within the multilayer capacitor. 
     In embodiments where at least two capacitors (e.g., C 1  and C 2 ) are connected within the multilayer capacitor, the electrodes of the two capacitors can extend in different directions to improve noise reduction. For example, the two capacitors can be stacked vertically relative to each other (e.g., stacked vertically in a z-direction). The electrodes of each capacitor C 1  and C 2  can be arranged parallel to an x-z plane and/or a y-z plane, and the electrodes of C 1  can extend perpendicular to the electrodes of C 2 . In this way, any deformations or piezoelectric distortions of C 1  can be countered by the deformations or piezoelectric distortions of C 2  when the multilayer capacitor is charged. 
     In embodiments where at least three capacitors (e.g., C 1 , C 2 , and C 3 ) are connected within the multilayer capacitor, the electrodes of each capacitor can be oriented differently to improve noise reduction. For example, capacitors C 1 , C 2 , and C 3  can be vertically stacked relative to each other. The capacitors can be monolithically bonded and separated by a dielectric layer that is composed of the same or a different material than the dielectric material that is included in one of the capacitors C  1 , C 2 , and C 3 . The capacitor C 2  can be disposed between the capacitors C 1  and C 3 , and can include electrodes that are horizontally oriented (e.g., parallel to an x-y plane). Furthermore, the capacitors C 1  and C 3  can include electrodes that are vertically oriented (e.g., parallel to an x-z plane and/or y-z plane). Each of the capacitors C 1 , C 2 , and C 3  can be electrically connected and monolithically bonded. In this way, the mechanical forces created when each capacitor is polarized can effectively be canceled out when summed, thereby reducing the amount of acoustic noise that would otherwise be generated. 
     In some embodiments, the multilayer capacitor can include one or more dielectric barriers or dead zones composed of at least partially non-plated dielectric layers that act to restrict deformation of the multilayer capacitor when the multilayer capacitor is polarized or otherwise receives a charge. Because the non-plated dielectric layers are monolithically bonded to the electrodes, they provide additional rigidity to the multilayer capacitor without inducing any piezoelectric effects when the multilayer capacitor is polarized. A dielectric barrier can be arranged within the multilayer capacitor in a variety of ways. The dielectric barrier can also take a variety of shapes, and multiple dielectric barriers of the same shape or different shapes can be incorporated into the multilayer capacitor. For example, in some embodiments, the dielectric barrier is a wall that extends between two or more capacitors of the multilayer capacitor. In other embodiments, the dielectric barrier is a wall that extends partially into a capacitor of the multilayer capacitor. In yet other embodiments, the dielectric barrier can be one or more pillars or columns in the center, the side, and/or the corner of the multilayer capacitor. The ceramic barrier can extend in one or more directions not limited to an x-direction, y-direction, and/or z-direction. Moreover, a cross section of at least a portion of a dielectric barrier can be a cross, circle, oval, line, square, polygon, or any combination thereof. Furthermore, non-plated dielectric layers can be different per layer of the multilayer capacitor. In one example, a non-plated dielectric layer can be cross-shaped and another layer of the non-plated dielectric layer can be a polygon at a corner or side of the multilayer capacitor. In another example, a non-plated dielectric layer can form a circle and another layer of the non-plated dielectric layer can form a larger or smaller circle than the circle of the non-plated dielectric layer. However, it should be noted that any combination of layers and shapes of layers is within the scope of this disclosure. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-11 ; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1A  illustrates a perspective view  100  of conductive electrodes that can be incorporated into a multilayer capacitor according to some embodiments discussed herein. Specifically,  FIG. 1A  includes a first array of conductive electrodes  102  and a second array of conductive electrodes  104 . The first array of conductive electrodes  102  can be arranged in a different direction than the second array of conductive electrodes  104 .  FIG. 1B  illustrates a perspective view  106  of each of the first array of conductive electrodes  102  and the second array of conductive electrodes  104  printed onto stacked dielectric layers  108 . In this way, a first capacitor  110  and a second capacitor  112  are created in an arrangement where the capacitors are monolithically joined. Portions of the first array of conductive electrodes  102  and the second array of conductive electrodes  104  can extend out of the dielectric  108  to create terminals, which can be soldered together, or otherwise coated with a conductive material, as illustrated in  FIG. 2 . 
       FIG. 2  illustrates a perspective view  200  of a multilayer capacitor arranged according to some embodiments discussed herein. The multilayer capacitor of  FIG. 2  includes the first array of conductive electrodes  102  and the second array of conductive electrodes  104  illustrated in  FIGS. 1A and 1B . However, the terminals extending from the dielectric  108  are soldered together in  FIG. 2  to create a first terminal  202  and a second terminal  204 . In this way, both the first capacitor  110  and the second capacitor  112  can be charged when the first terminal  202  and the second terminal  204  receive a voltage. Additionally, because of the arrangement of the first array of conductive electrodes  102  and the second array of conductive electrodes  104 , the first capacitor  110  and the second capacitor  112  will deform in different directions when receiving the voltage. As a result, an amount of deformation of the multilayer capacitor is reduced, compared to a capacitor having electrodes that are all arranged in the same direction. The reduction in deformation results in less noise generated during operation of the multilayer capacitor provided in  FIG. 2 . Furthermore, when the multilayer capacitor is connected to a circuit, less voltage will be induced in the circuit when the multilayer capacitor receives a vibration. When less voltage is induced in the circuit as a result of vibration, performance of the circuit is improved. 
       FIG. 3A  illustrates a perspective view  300  of conductive electrodes that can be incorporated into a multilayer capacitor according to some embodiments discussed herein. Specifically,  FIG. 3A  includes a first array of electrodes  302 , a second array of electrodes  304 , and a third array of electrodes  306 . The first array of electrodes  302  can be arranged in a different orientation than the second array of electrodes  304  and the third array of electrodes  306 .  FIG. 3B  illustrates a perspective view  308  of the first array of electrodes  302 , the second array of electrodes  304 , and the third array of electrodes  306  printed onto multiple dielectric layers  310 . In this way, a first capacitor  312 , a second capacitor  314 , and a third capacitor  316  are created in an arrangement where the capacitors are monolithically joined. Portions of the first array of electrodes  302 , the second array of electrodes  304 , and the third array of electrodes  306  can extend out of the dielectric  310  to create terminals, which can be soldered together as illustrated in  FIG. 4 . 
       FIG. 4  illustrates a perspective view  400  of a multilayer capacitor arranged according to some embodiments discussed herein. The multilayer capacitor of  FIG. 4  can include the first array of electrodes  302 , the second array of electrodes  304 , and the third array of electrodes  306  illustrated in  FIGS. 3A and 3B . However, the terminals extending from the dielectric  310  are soldered together in  FIG. 4  to create a first terminal  402  and a second terminal  404 . In this way, the first capacitor  312 , the second capacitor  314 , and the third capacitor  316  can be charged when the first terminal  402  and the second terminal  404  receive a voltage. Additionally, because of the arrangement of the first array of electrodes  302 , the second array of electrodes  304 , and the third array of electrodes  306 , the first capacitor  312 , the second capacitor  314 , and the third capacitor  316  will deform in different directions when receiving the voltage. As a result, an amount of deformation of the multilayer capacitor is reduced, compared to a capacitor having electrodes that are all arranged in the same direction, as discussed herein. 
       FIG. 5A  illustrates a perspective view  500  of conductive electrodes that can be printed onto one or more dielectric layers and incorporated into a multilayer capacitor according to some embodiments discussed herein. Specifically,  FIG. 5A  includes a first array of conductive electrodes  502  adjacent to a second array of conductive electrodes  504 . The electrodes of each array of conductive electrodes partially overlap each other. In this way, the ends of some electrodes overlap at least some of the ends of the other electrodes within the same array. This is useful when creating terminals of the capacitor in which the array of electrodes is disposed.  FIG. 5B  illustrates a perspective view  506  of a multilayer capacitor that includes the first array of conductive electrodes  502  and the second array of conductive electrodes  504  printed and stacked onto multiple dielectric layers  508 . By printing the first array of conductive electrodes  502  and the second array of conductive electrodes  504  onto the dielectric layers  508 , a first capacitor  510  and a second capacitor  512  are formed within the multilayer capacitor. Because of the separation of the first array of conductive electrodes  502  and the second array of conductive electrodes  504  within the multilayer capacitor of  FIG. 5B , a dead zone can be created between the first capacitor  510  and the second capacitor  512 . The dead zone refers to an area of the multilayer capacitor that resists movement when one or more of the first capacitor  510  and the second capacitor  512  are charged. The dead zone can be made of the same material as the dielectric layers  508  or a different material, as seen in  FIG. 6A . 
       FIG. 6A  illustrates a perspective view  600  of a multilayer capacitor with a dead zone  602  to resist deformation of the multilayer capacitor. The dead zone  602  can be formed from the same material as the dielectric layers  508  or a different material that is more or less rigid than the dielectric layers  508 . The dead zone  602  can have a width of 100 microns or less. In some embodiments, the dead zone  602  can have a width of 60 microns, plus or minus 10 microns. The width of the dead zone  602  can be a distance between the first array of conductive electrodes  502  and the second array of conductive electrodes  504 . Furthermore, each of the first capacitor  510  and the second capacitor  512  can be arranged to deform in different or opposing directions when receiving a charge or voltage. A first terminal  606  and a second terminal  608  can be created at the multilayer capacitor illustrated in the perspective view  604  of  FIG. 6B . The first terminal  606  and the second terminal  608  can be formed from solder or other conductive bonding material in order to create a conductive pathway between the first array of conductive electrodes  502  and the second array of conductive electrodes  504 . In this way, when the first terminal  606  and the second terminal  608  receive a charge, the first capacitor  510  and the second capacitor  512  will deform in different directions, and their deformation will be physically resisted by the dead zone  602 . 
       FIG. 7A  illustrates a perspective view  700  of conductive electrodes that can be incorporated into a multilayer capacitor in an arrangement that creates a dead zone in at least two directions. Specifically,  FIG. 7A  includes a first array of conductive electrodes  714  adjacent to a second array of conductive electrodes  716 . The electrodes of each array of conductive electrodes partially overlap each other. In this way, the ends of some electrodes overlap at least some of the ends of the other electrodes within the same array. This is useful when creating terminals of the capacitor in which the array of electrodes is disposed. Furthermore, the first array of conductive electrodes  714  and the second array of conductive electrodes  716  can be arranged in groups in order to leave a gap or space between groups, thereby creating a dead zone  704 . When the groups of the first array of conductive electrodes  714  and the second array of conductive electrodes  716  are printed on the dielectric layers  722  and thereafter stacked, cut, and baked, a dielectric dead zone  708  can be created, as illustrated in  FIG. 7B . Specifically,  FIG. 7B  illustrates a perspective view  702  of a cross section of a multilayer capacitor that includes the dielectric dead zone  708  between groups of conductive electrodes. Each group of conductive electrodes, which are separated by the dielectric dead zone  708 , can each create a capacitor within the multilayer capacitor. For example, a first capacitor  710 , a second capacitor  712 , a third capacitor  718 , and a fourth capacitor  720  can be created within the multilayer capacitor. Conductive electrodes  714  and conductive electrodes  716  can extend from dielectric layers  722  of the multilayer capacitor to help create terminals for the first capacitor  710 , the second capacitor  712 , the third capacitor  718 , and the fourth capacitor  720 . The multilayer capacitor can be coated with a conductive material to create a conductive terminal  706 , as illustrated in the cross section of  FIG. 7B . When the terminals of the multilayer capacitor of  FIG. 7B  receive a charge or voltage, the dead zone  708  between the first capacitor  710 , the second capacitor  712 , the third capacitor  718 , and the fourth capacitor  720  will resist deforming. As a result, any noise exhibited by the multilayer capacitor of  FIG. 7B  can be reduced, and the structural integrity of the multilayer capacitor can be improved. 
       FIG. 8A  illustrates a cut away view  800  of a multilayer capacitor that includes a circular dead zone  802 . When the multilayer capacitor is completely assembled, a dielectric layer  806  (e.g., ceramic layer) would envelope one or more conductive electrodes  808 ; however, the cut away view  800  illustrates dielectric layers  806  that are partially cut away and one of two terminals  804  of the multilayer capacitor removed to show the circular dead zone  802 . The circular dead zone  802  can include a circular region  802 A that is joined with a rectangular region  802 B. The term dead zone can refer to a volume of the multilayer capacitor that does not include regions of conductive electrodes  808 . In this way, when the conductive electrodes  808  are printed onto the dielectric layers  806 , and thereafter stacked, pressed, cut, and baked, a dielectric barrier or dead zone will be created in the circular region  802 A and the rectangular region  802 B. Each of the conductive electrodes  808  can be printed onto at least one dielectric layer  806  to form the circular dead zone  802 . The radius of the circular region  802 A on each dielectric layer  806  can be constant or variable as each conductive electrode  808  is printed onto each dielectric layer  806 . In this way, the circular dead zone  802  can resemble a circular column that has the same radius or a varying radius as the column extends through the multilayer capacitor. The circular dead zone  802  can resist deformation, which can occur when the multilayer capacitor of  FIG. 8A  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. 
       FIG. 8B  illustrates a cut away view  810  of a multilayer capacitor that includes an oval dead zone  812 . The cut away view  810  illustrates dielectric layers  806  that are partially cut away and one of the two terminals  804  of the multilayer capacitor being removed to show the oval dead zone  812 . The oval dead zone  812  can include an oval region  812 A that is joined with a rectangular region  812 B. In this way, when the conductive electrodes  814  are printed onto the dielectric layer  806 , and thereafter stacked, pressed, cut, and baked, a dielectric barrier will be created in the oval region  812 A and the rectangular region  812 B. Each of the conductive electrodes  814  can be printed onto at least one dielectric layer  806  to form the oval dead zone  812 . The dimensions of the oval printed onto each dielectric layer  806  can be constant or variable as each conductive electrode  808  is printed onto the dielectric layers  806 . In this way, the oval dead zone  812  can resemble an oval column that has the same dimensions or a varying dimensions as the column extends through the multilayer capacitor. As a result, the oval dead zone  812  can resist deformation, which can occur when the multilayer capacitor of  FIG. 8B  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. 
       FIG. 8C  illustrates a cut away view  820  of a multilayer capacitor that includes a cross dead zone  816 . The cut away view  820  illustrates dielectric layers  806  that are partially cut away and one of the two terminals  804  of the multilayer capacitor being removed to show the cross dead zone  816 . The cross dead zone  816  can be defined by a conductive electrode  818  that is printed onto a dielectric layer  806  such that a cross-shaped region on the dielectric layer  806  does not include conductive material. In this way, when the conductive electrodes  818  are printed onto the dielectric layers  806 , and thereafter stacked, pressed, cut, and baked, a dielectric barrier will extend through the conductive electrodes  818 . The dimensions of the cross dead zone  816  printed on each of the dielectric layers  806  can be constant or variable as each conductive electrode  818  is printed onto each dielectric layer  806 . In this way, the cross dead zone  816  can resemble intersecting walls that have the same dimensions or varying dimensions as the walls extend through the multilayer capacitor. As a result, the cross dead zone  816  can resist deformation, which can occur when the multilayer capacitor of  FIG. 8C  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. 
       FIG. 8D  illustrates a cut away view  822  of a multilayer capacitor that includes a multi-cross dead zone  824 . The cut away view  822  illustrates dielectric layers  806  that are partially cut away and one of the two terminals  804  of the multilayer capacitor being removed to show the multi-cross dead zone  824 . The multi-cross dead zone  824  can be defined by a rectangle that is intersected by one or more other rectangles. The various rectangles of the multi-cross dead zone  824  can intersect at an angle of approximately 90 degrees, less than 90 degrees, or greater than 90 degrees. When the conductive electrodes  826  are printed onto the dielectric layer  806 , and thereafter stacked, pressed, cut, and fired, a dielectric barrier will extend through the multiple cross-shaped regions of the conductive electrodes  826 . Each of the conductive electrodes  826  can be printed onto each dielectric layer  806  to form the multi-cross dead zone  824 . The dimensions of the crosses in each of the conductive electrodes  826  can be constant or variable as each conductive electrode  826  is printed and stacked. In this way, the multi-cross dead zone can resemble intersecting walls that have the same dimensions or varying dimensions as the walls extend through the multilayer capacitor. As a result, the multi-cross dead zone  824  can resist deformation, which can occur when the multilayer capacitor of  FIG. 8C  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. 
       FIG. 9A  illustrates a cut away view  900  of a multilayer capacitor that includes a circular dead zone  908 . The cut away view  900  illustrates dielectric layers  806  that are partially cut away and one of the two terminals  804  of the multilayer capacitor removed to show the circular dead zone  908 . The circular dead zone  908  can be defined by a circular region that is outlined by an edge of a conductive electrode  906 , which is printed on a dielectric layer  806 . When the conductive electrodes  906  are printed on the dielectric layers  806 , and thereafter stacked, pressed, cut, and baked, a dielectric barrier will extend through the circular regions of each conductive electrode  906 . In some embodiments, the multilayer capacitor can be arranged to include multiple dielectric barriers defined by multiple circular regions extending through different areas of the conductive electrodes  906 . Each of the conductive electrodes  906  can be individually printed on the dielectric layers  806  to form the circular dead zone  908 . The dimensions of the circular region in each of the conductive electrodes  906  can be constant or variable as each conductive electrode  906  is printed and stacked. In this way, the circular dead zone  908  can resemble a column having a constant or variable radius as the column extends through the multilayer capacitor of  FIG. 9A . As a result, the circular dead zone  908  can resist deformation, which can occur when the multilayer capacitor of  FIG. 9A  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. 
       FIG. 9B  illustrates a cut away view  902  of a multilayer capacitor that includes an oval dead zone  910 . The cut away view  902  illustrates dielectric layers  806  that are partially cut away and one of the two terminals  804  of the multilayer capacitor removed to show the oval dead zone  910 . The oval dead zone  910  can be defined by an oval region that is outlined by an edge of the conductive electrode  912 , which is printed on one or more dielectric layers  806 . When the conductive electrodes  912  are printed on the dielectric layers  806 , and thereafter stacked, pressed, cut, and baked, a dielectric barrier will extend through the oval regions of each conductive electrode  912 . The dimensions of the oval region in each of the conductive electrodes  912  can be constant or variable as each conductive electrode  906  is printed onto each dielectric layer  806 . In this way, the oval dead zone  910  can resemble a column having a constant or variable radius as the column extends through the multilayer capacitor of  FIG. 9B . As a result, the oval dead zone  910  can resist deformation, which can occur when the multilayer capacitor of  FIG. 9B  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. 
       FIG. 9C  illustrates a cut away view  904  of a multilayer capacitor that includes one or more perimeter dead zones  914 . The cut away view  904  illustrates dielectric layers  806  that are partially cut away, and one of the two terminals  804  of the multilayer capacitor removed, to show the perimeter dead zones  914 . The perimeter dead zones  914  can be defined by a printed edge of the conductive electrodes  916  that extends away from a boundary of at least one of the conductive electrodes  916 . When the conductive electrodes  916  are printed onto the dielectric layer  806 , and thereafter stacked, pressed, cut, and baked, a dielectric barrier will extend through each conductive electrode  916 . Each of the conductive electrodes can be individually printed onto a dielectric layer  806  to form the perimeter dead zones  914 . The dimensions of the conductive electrodes  916  can be constant or variable as each conductive electrode  916  is printed onto a dielectric layer  806 . In this way, the perimeter dead zones  914  can resemble columns having constant or variable dimensions as the columns extend through the multilayer capacitor of  FIG. 9C . As a result, the perimeter dead zones  914  can resist deformation, which can occur when the multilayer capacitor of  FIG. 9C  is charged, thereby reducing an amount of acoustic noise exhibited by the multilayer capacitor. It should be noted that any of the embodiments discussed herein, including those related to  FIGS. 1A-9C  can be modified and/or combined in any manner suitable for creating a capacitor that has noise cancelling properties. For example, any of the embodiments discussed with respect to  FIGS. 8A-9C  can be stacked or arranged according to the embodiments of  FIGS. 2 and 4 , or  FIGS. 6A-7B . 
       FIG. 10  illustrates an exploded view  1000  of an embodiment of a combination of conductive electrodes that can be incorporated into any of the multilayer capacitors discussed herein. Specifically,  FIG. 10  illustrates a first conductive electrode  1002  that can be printed onto a dielectric layer (not shown) and arranged over a second conductive electrode  1004  within a multilayer capacitor. The first conductive electrode  1002  can be printed to have a cross-shaped cutout region and the second conductive electrode  1004  can be printed to have one or more cutout edge regions. As a result, a more rigid structure will be created for the multilayer capacitor when the first conductive electrode  1002  and the second conductive electrode  1004  are stacked. This arrangement causes the multilayer capacitor to resist deformation when the multilayer capacitor of  FIG. 10  is charged. It should be noted that any combination of two or more different conductive electrodes can be printed and stacked to form a multilayer capacitor. For example, in some embodiments, a multilayer capacitor is arranged to include the conductive electrode  906  of  FIG. 9A  disposed over the conductive electrode  916  of  FIG. 9C . 
       FIG. 11  illustrates a method  1100  for forming a multilayer capacitor according to any of the embodiments discussed herein. The method  1100  can be performed by any computing, apparatus, or machine suitable for manufacturing capacitors. The method  1100  can include a step  1102  of printing conductive electrodes onto dielectric layers. Printing can be performed by applying a conductive ink onto one or more layers of dielectric material. The method  1100  can further include a step  1104  of stacking the dielectric layers and conductive electrodes to create a multilayer component. Thereafter, at step  1106 , the multilayer component can be laminated for bonding the dielectric layers and the conductive electrodes. Laminating the multilayer component results in a monolithic bond between the multiple layers of conductive electrodes and dielectric layers. At step  1108 , the multilayer component is cut into individual capacitors. In some embodiments, the individual capacitors can include at least 400 layers and have a capacitance of at least 15 microfarads. Furthermore, in some embodiments, the individual capacitors can have dimensions less than or equal to 1.2 millimeters in length, by 0.65 millimeters in width, and by 0.65 millimeters in height. Individual layers of dielectric and conductive material can each have a thickness of less than or equal to 0.5 micrometers. The method  1100  can further include a step of baking the individual capacitors in a kiln or other receptacle for baking or firing an electronic component. At step  1112 , the capacitors can be coated with a conductive material to form terminals on the capacitors. For example, the coating process can be performed by electroplating the capacitors with a layer of the conductive material, such as nickel, tin, aluminum, alloy, and/or any other suitable material for creating a terminal. It should be noted that step  1112  can be repeated for creating any number of terminals for the capacitors. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data, which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20160331
Publication Date: 20190115
Grant Date: 20190115
Priority Date: 20150921
Inventors: MARTINEZ, PAUL A.
SAUERS, JASON C.
ARNOLD, Shawn X.
Assignee: APPLE INC
CPC Classifications: [{"code": "A62C31/22", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01G4/012", "inventive": true, "first": false, "tree": "[]"}, {"code": "A62C31/22", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01G4/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "A62C33/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/1218", "inventive": true, "first": false, "tree": "[]"}, {"code": "E06B5/162", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/232", "inventive": true, "first": false, "tree": "[]"}, {"code": "E06B5/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "A62C31/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "A62C31/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01G4/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "A62C33/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10015", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "F16L5/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10015", "inventive": false, "first": false, "tree": "[]"}, {"code": "A62C33/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "A62C31/22", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01G4/1218", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/232", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "F16L5/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/012", "inventive": true, "first": false, "tree": "[]"}, {"code": "A62C31/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "E06B5/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "E06B5/162", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01G4/30", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 62244639