Multilayer ceramic capacitors

Abstract

Provided is a layered ceramic capacitor with which it is possible to improve both moisture resistance and high-temperature reliability.　In a layered ceramic capacitor 1 according to the present embodiment, an effective layer part 11E in which a plurality of internal electrode layers 30 face each other in a height direction T in a laminate 10, includes a first side-surface-side effective layer part 11E1, a second side-surface-side effective layer part 11E2, and a central-section-side effective layer part 11EC. The average height-direction T thickness of dielectric layers 20 within the first side-surface-side effective layer part 11E1 and the second side-surface-side effective layer part 11E2 is less than the average height-direction T thickness of dielectric layers 20 within the central-section-side effective layer part 11EC. The average particle diameter of a ceramic material in the dielectric layers 20 within the first side-surface-side effective layer part 11E1 and the second side-surface-side effective layer part 11E2 is greater than the average particle diameter of a ceramic material in the dielectric layers 20 within the central-section-side effective layer part 11EC.

Description

[Technical Field]

[0001] The present invention relates to a multilayer ceramic capacitor. [Background technology]

[0002] Multilayer ceramic capacitors have been known for some time. Generally, multilayer ceramic capacitors include a ceramic sintered body made of a dielectric ceramic such as barium titanate. A plurality of internal electrodes are arranged inside the ceramic sintered body so as to overlap each other with ceramic layers interposed therebetween. Furthermore, external electrodes are formed on one end surface and the other end surface of the ceramic sintered body so as to be electrically connected to the internal electrodes (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 8-306580 Summary of the Invention [Problem to be solved by the invention]

[0004] Meanwhile, various measures have been taken to ensure high-temperature reliability for multilayer ceramic capacitors, such as moisture resistance against steam and other elements, and to meet the required performance even under high-temperature loads, and further improvements in performance are being sought.

[0005] An object of the present invention is to provide a multilayer ceramic capacitor that can improve both moisture resistance and high-temperature reliability. [Means for solving the problem]

[0006] The multilayer ceramic capacitor according to the present invention has a laminate including a plurality of laminated dielectric layers and a plurality of laminated internal electrode layers, a first main surface and a second main surface opposing each other in a height direction, a first side surface and a second side surface opposing each other in a width direction perpendicular to the height direction, and a first end surface and a second end surface opposing each other in a length direction perpendicular to the height direction and the width direction, and has an effective layer portion where the plurality of internal electrode layers are opposed to each other in the height direction via the dielectric layer, wherein the dielectric layer includes a ceramic material, and the effective layer portion includes a first side edge extending in the height direction on the first side surface side and a second side edge extending in the height direction on the second side surface side, and The dielectric layer includes a first side surface side effective layer portion including a region extending in a width direction toward the inside of the effective layer portion, a second side surface side effective layer portion including a region extending from the second side surface side edge toward the inside of the effective layer portion in a width direction, and a central side effective layer portion including a region near the center of the effective layer portion in the width direction, wherein the average thickness in the height direction of the dielectric layer present inside the first side surface side effective layer portion and the second side surface side effective layer portion is thinner than the average thickness in the height direction of the dielectric layer present inside the central side effective layer portion, and the average particle diameter of the ceramic material in the dielectric layer present inside the first side surface side effective layer portion and the second side surface side effective layer portion is larger than the average particle diameter of the ceramic material of the dielectric layer present inside the central side effective layer portion. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a multilayer ceramic capacitor that can improve both moisture resistance and high-temperature reliability. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is an external perspective view of a multilayer ceramic capacitor according to an embodiment; [Figure 2] 2 is a cross-sectional view taken along line II-II of the multilayer ceramic capacitor shown in FIG. [Figure 3] 3 is a cross-sectional view taken along line III-III of the multilayer ceramic capacitor shown in FIG. 2. [Figure 4] 4 is a cross-sectional view taken along line IV-IV of the multilayer ceramic capacitor shown in FIG. 2. [Figure 5] 10 is an example of an enlarged image of a cross section of an exposed effective layer portion. [Figure 6] FIG. 1 is a diagram showing a multilayer ceramic capacitor with a double structure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a multilayer ceramic capacitor 1 according to an embodiment of the present disclosure will be described. Fig. 1 is an external perspective view of the multilayer ceramic capacitor 1 of this embodiment. Fig. 2 is a cross-sectional view taken along line II-II of the multilayer ceramic capacitor 1 of Fig. 1. Fig. 3 is a cross-sectional view taken along line III-III of the multilayer ceramic capacitor 1 of Fig. 2. Fig. 4 is a cross-sectional view taken along line IV-IV of the multilayer ceramic capacitor 1 of Fig. 2.

[0010] The multilayer ceramic capacitor 1 includes a laminate 10 and external electrodes 40.

[0011] 1 to 4 show an XYZ Cartesian coordinate system. The length direction L of the multilayer ceramic capacitor 1 and the laminate 10 corresponds to the X direction. The width direction W of the multilayer ceramic capacitor 1 and the laminate 10 corresponds to the Y direction. The height direction T of the multilayer ceramic capacitor 1 and the laminate 10 corresponds to the Z direction. Here, the cross section shown in FIG. 2 is also referred to as the LT cross section. The cross section shown in FIG. 3 is also referred to as the WT cross section. The cross section shown in FIG. 4 is also referred to as the LW cross section.

[0012] As shown in Figures 1 to 4, the laminate 10 includes a first main surface TS1 and a second main surface TS2 facing each other in a height direction T, a first side surface WS1 and a second side surface WS2 facing each other in a width direction W perpendicular to the height direction T, and a first end surface LS1 and a second end surface LS2 facing each other in a length direction L perpendicular to the height direction T and the width direction W.

[0013] As shown in FIG. 1, the laminate 10 has a substantially rectangular parallelepiped shape. The dimension of the laminate 10 in the length direction L is not necessarily longer than the dimension in the width direction W. The corners and ridges of the laminate 10 are preferably rounded. A corner is a portion where three surfaces of the laminate intersect, and a ridge is a portion where two surfaces of the laminate intersect. Incidentally, unevenness may be formed on part or all of the surfaces constituting the laminate 10.

[0014] As shown in Figures 2 and 3, the laminate 10 has an inner layer portion 11, and a first main surface side outer layer portion 12 and a second main surface side outer layer portion 13 arranged to sandwich the inner layer portion 11 in the height direction T.

[0015] The inner layer portion 11 includes a plurality of dielectric layers 20 and a plurality of internal electrode layers 30. In the height direction T, the inner layer portion 11 includes the inner electrode layer 30 located closest to the first principal surface TS1 to the inner electrode layer 30 located closest to the second principal surface TS2. In the inner layer portion 11, the plurality of internal electrode layers 30 are arranged opposite each other with the dielectric layer 20 interposed therebetween. The inner layer portion 11 is a portion that generates electrostatic capacitance and essentially functions as a capacitor.

[0016] The plurality of dielectric layers 20 are made of a dielectric material. The ceramic material in the dielectric layers has a perovskite structure containing Ba, Sr, Zr, Ti, Hf, and Si, and optionally containing Ca, and preferably has a ratio of Sr moles / (Ba moles + Ca moles + Sr moles) of 0.6 to 0.95, and a ratio of Zr moles / (Zr moles + Ti moles + Hf moles) of 0.9 to 0.98.

[0017] By selecting the above materials and compositions, there is an advantage that good temperature characteristics can be ensured.

[0018] Furthermore, it is more preferable that the ceramic material in the dielectric layer has a perovskite structure containing Ba, Sr, Zr, Ti, Hf, and Si, and optionally containing Ca, and that (number of moles of Ba + number of moles of Ca + number of moles of Sr) / (number of moles of Zr + number of moles of Ti + number of moles of Hf) is 1.00 or more and 1.03 or less.

[0019] By selecting the above materials and compositions, oxygen defects in the dielectric can be suppressed during firing in a reducing atmosphere, which provides the further advantage of improving reliability.

[0020] The thickness of the dielectric layer 20 is preferably 0.7 μm or more and 2.5 μm or less. The number of laminated dielectric layers 20 is preferably 10 or more and 1500 or less. Note that this number of dielectric layers 20 is the total number of the dielectric layers in the inner layer portion 11 and the dielectric layers in the first main surface side outer layer portion 12 and the second main surface side outer layer portion 13.

[0021] The multiple internal electrode layers 30 include multiple first internal electrode layers 31 and multiple second internal electrode layers 32. The multiple first internal electrode layers 31 are arranged on the multiple dielectric layers 20. The multiple second internal electrode layers 32 are arranged on the multiple dielectric layers 20. The multiple first internal electrode layers 31 and the multiple second internal electrode layers 32 are arranged alternately in the height direction T of the laminate 10, with the dielectric layers 20 interposed between them. The first internal electrode layers 31 and the second internal electrode layers 32 are arranged so as to sandwich the dielectric layers 20 therebetween.

[0022] The first internal electrode layer 31 has a first opposing portion 31A opposing the second internal electrode layer 32, and a first lead portion 31B led from the first opposing portion 31A to the first end face LS1. The first lead portion 31B is exposed at the first end face LS1.

[0023] The second internal electrode layer 32 has a second opposing portion 32A opposing the first internal electrode layer 31, and a second lead portion 32B led from the second opposing portion 32A to the second end face LS2. The second lead portion 32B is exposed at the second end face LS2.

[0024] In this embodiment, the first opposing portion 31A and the second opposing portion 32A face each other via the dielectric layer 20, thereby forming capacitance and exhibiting the characteristics of a capacitor.

[0025] The shapes of the first opposing portion 31A and the second opposing portion 32A are not particularly limited, but are preferably rectangular. However, the corners of the rectangular shape may be rounded or the corners of the rectangular shape may be formed at an angle. The shapes of the first drawer portion 31B and the second drawer portion 32B are not particularly limited, but are preferably rectangular. However, the corners of the rectangular shape may be rounded or the corners of the rectangular shape may be formed at an angle.

[0026] The width direction W dimension of the first facing portion 31A and the width direction W dimension of the first lead portion 31B may be the same dimension, or one of the dimensions may be smaller. The width direction W dimension of the second facing portion 32A and the width direction W dimension of the second lead portion 32B may be the same dimension, or one of the dimensions may be smaller.

[0027] The first internal electrode layer 31 and the second internal electrode layer 32 are made of an appropriate conductive material, such as a metal such as Ni, Cu, Ag, Pd, or Au, or an alloy containing at least one of these metals. When an alloy is used, the first internal electrode layer 31 and the second internal electrode layer 32 may be made of, for example, an Ag-Pd alloy.

[0028] The thickness of each of the first internal electrode layers 31 and the second internal electrode layers 32 is preferably, for example, about 0.2 μm or more and 1.5 μm or less. The total number of the first internal electrode layers 31 and the second internal electrode layers 32 is preferably 10 or more and 1500 or less.

[0029] Sn may be disposed at the interface between the first internal electrode layer and the dielectric layer and at the interface between the second internal electrode layer and the dielectric layer. Sn may be layered or scattered. Sn may be solid-dissolved on the internal electrode side or in the dielectric grains on the dielectric layer side.

[0030] The first main surface side outer layer portion 12 is located on the first main surface TS1 side of the laminate 10. The first main surface side outer layer portion 12 is an assembly of multiple dielectric layers 20 located between the first main surface TS1 and the internal electrode layer 30 closest to the first main surface TS1. The dielectric layers 20 used in the first main surface side outer layer portion 12 may be the same as the dielectric layers 20 used in the internal layer portion 11.

[0031] The second main surface side outer layer portion 13 is located on the second main surface TS2 side of the laminate 10. The second main surface side outer layer portion 13 is an assembly of multiple dielectric layers 20 located between the second main surface TS2 and the internal electrode layer 30 closest to the second main surface TS2. The dielectric layers 20 used in the second main surface side outer layer portion 13 may be the same as the dielectric layers 20 used in the internal layer portion 11.

[0032] In this way, the laminate 10 has a plurality of laminated dielectric layers 20 and a plurality of internal electrode layers 30 laminated on the dielectric layers 20. In other words, the multilayer ceramic capacitor 1 has a laminate 10 in which the dielectric layers 20 and the internal electrode layers 30 are alternately laminated.

[0033] The laminate 10 has an effective layer portion 11E. The effective layer portion 11E is the portion where the first opposing portion 31A of the first internal electrode layer 31 and the second opposing portion 32A of the second internal electrode layer 32 face each other. The effective layer portion 11E is configured as a part of the internal layer portion 11. FIG. 4 shows the range of the effective layer portion 11E in the width direction W and length direction L. The effective layer portion 11E is also called an opposing electrode portion or a capacitor effective portion. Details of the effective layer portion 11E will be described later.

[0034] The laminate 10 has side surface outer layer portions. The side surface outer layer portions include a first side surface outer layer portion WG1 and a second side surface outer layer portion WG2. The first side surface outer layer portion WG1 is a portion including the dielectric layer 20 located between the effective layer portion 11E and the first side surface WS1. The second side surface outer layer portion WG2 is a portion including the dielectric layer 20 located between the effective layer portion 11E and the second side surface WS2. Figures 3 and 4 show the ranges in the width direction W of the first side surface outer layer portion WG1 and the second side surface outer layer portion WG2. The side surface outer layer portions are also called W gaps or side gaps.

[0035] The laminate 10 has end-side outer layer portions. The end-side outer layer portions include a first end-side outer layer portion LG1 and a second end-side outer layer portion LG2. The first end-side outer layer portion LG1 is a portion including the dielectric layer 20 located between the effective layer portion 11E and the first end face LS1. The second end-side outer layer portion LG2 is a portion including the dielectric layer 20 located between the effective layer portion 11E and the second end face LS2. Figures 2 and 4 show the ranges in the length direction L of the first end-side outer layer portion LG1 and the second end-side outer layer portion LG2. The end-side outer layer portions are also referred to as L gaps or end gaps.

[0036] The external electrode 40 has a first external electrode 40A arranged on the first end face LS1 side and a second external electrode 40B arranged on the second end face LS2 side.

[0037] The first external electrode 40A is disposed on the first end face LS1. The first external electrode 40A is connected to the first internal electrode layer 31. The first external electrode 40A may also be disposed on a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2. In this embodiment, the first external electrode 40A is formed to extend from the first end face LS1 to a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2.

[0038] The second external electrode 40B is disposed on the second end face LS2. The second external electrode 40B is connected to the second internal electrode layer 32. The second external electrode 40B may also be disposed on a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2. In this embodiment, the second external electrode 40B is formed to extend from the second end face LS2 to a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2.

[0039] As described above, in the laminate 10, the first opposing portion 31A of the first internal electrode layer 31 and the second opposing portion 32A of the second internal electrode layer 32 face each other via the dielectric layer 20, thereby forming a capacitance. Therefore, the characteristics of a capacitor are exhibited between the first external electrode 40A connected to the first internal electrode layer 31 and the second external electrode 40B connected to the second internal electrode layer 32.

[0040] The first external electrode 40A has a first base electrode layer 50A and a first plating layer 60A disposed on the first base electrode layer 50A.

[0041] The second external electrode 40B has a second base electrode layer 50B and a second plating layer 60B disposed on the second base electrode layer 50B.

[0042] The first base electrode layer 50A is disposed on the first end face LS1. The first base electrode layer 50A is connected to the first internal electrode layer 31. In this embodiment, the first base electrode layer 50A is formed to extend from the first end face LS1 to a portion of the first main surface TS1, a portion of the second main surface TS2, and a portion of the first side surface WS1 and a portion of the second side surface WS2.

[0043] The second base electrode layer 50B is disposed on the second end face LS2. The second base electrode layer 50B is connected to the second internal electrode layer 32. In this embodiment, the second base electrode layer 50B is formed to extend from the second end face LS2 to a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2. The first base electrode layer may be disposed only on the surface of the first end face of the laminate, and the second base electrode layer may be disposed only on the surface of the second end face of the laminate.

[0044] The first base electrode layer 50A and the second base electrode layer 50B of this embodiment are baked layers. The baked layers preferably contain a metal component and a glass component. The metal component includes at least one selected from, for example, Cu, Ni, Ag, Pd, an Ag-Pd alloy, and Au. The glass component includes at least one selected from, for example, B, Si, Ba, Mg, Al, and Li.

[0045] The baked layer is formed by, for example, applying a conductive paste containing glass and metal to the laminate and baking it. The baked layer may be formed by simultaneously firing a laminated chip having internal electrodes and a dielectric layer with a conductive paste applied to the laminated chip, or by firing a laminated chip having internal electrodes and a dielectric layer to obtain a laminate, and then applying a conductive paste to the laminate and baking it. In addition, when simultaneously firing a laminated chip having internal electrodes and a dielectric layer with a conductive paste applied to the laminated chip, it is preferable to form the baked layer by adding a dielectric material instead of the glass component and baking it. The baked layer may be formed in multiple layers.

[0046] The thickness in the longitudinal direction L of the first base electrode layer 50A located on the first end surface LS1 is preferably, for example, approximately 3 μm or more and 160 μm or less at the center in the height direction T and width direction W of the first base electrode layer 50A.

[0047] The thickness in the length direction L of the second base electrode layer 50B located on the second end surface LS2 is preferably, for example, approximately 3 μm or more and 160 μm or less at the center in the height direction T and width direction W of the second base electrode layer 50B.

[0048] When the first base electrode layer 50A is provided on a portion of at least one of the first main surface TS1 or the second main surface TS2, the thickness in the height direction T of the first base electrode layer 50A provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and width direction W of the first base electrode layer 50A provided on this portion.

[0049] When the first base electrode layer 50A is provided on a portion of at least one of the first side surface WS1 or the second side surface WS2, it is preferable that the thickness in the width direction W of the first base electrode layer 50A provided on this portion is, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and height direction T of the first base electrode layer 50A provided on this portion.

[0050] When the second base electrode layer 50B is provided on a portion of at least one of the first main surface TS1 or the second main surface TS2, the thickness in the height direction T of the second base electrode layer 50B provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and width direction W of the second base electrode layer 50B provided on this portion.

[0051] When the second base electrode layer 50B is provided on a portion of at least one of the first side surface WS1 or the second side surface WS2, the thickness in the width direction W of the second base electrode layer 50B provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and height direction T of the second base electrode layer 50B provided on this portion.

[0052] The first and second base electrode layers 50A and 50B are not limited to baked layers. The first and second base electrode layers 50A and 50B may include at least one selected from baked layers, conductive resin layers, thin film layers, and the like. For example, the first and second base electrode layers 50A and 50B may be thin film layers. The thin film layers are formed by thin film formation methods such as sputtering or vapor deposition. The thin film layers are layers of metal particles deposited to a thickness of 1 μm or less.

[0053] The first plating layer 60A is disposed so as to cover the first base electrode layer 50A.

[0054] The second plating layer 60B is disposed so as to cover the second base electrode layer 50B.

[0055] The first plating layer 60A and the second plating layer 60B may contain at least one selected from, for example, Cu, Ni, Sn, Ag, Pd, an Ag-Pd alloy, and Au. The first plating layer 60A and the second plating layer 60B may each be formed of multiple layers. The first plating layer 60A and the second plating layer 60B preferably have a two-layer structure in which a Sn plating layer is formed on a Ni plating layer.

[0056] In this embodiment, the first plating layer 60A has a first Ni plating layer 61A and a first Sn plating layer 62A located on the first Ni plating layer 61A.

[0057] In this embodiment, the second plating layer 60B has a second Ni plating layer 61B and a second Sn plating layer 62B located on the second Ni plating layer 61B.

[0058] The Ni plating layer prevents the first base electrode layer 50A and the second base electrode layer 50B from being eroded by solder when mounting the multilayer ceramic capacitor 1. The Sn plating layer improves the wettability of the solder when mounting the multilayer ceramic capacitor 1, thereby facilitating mounting of the multilayer ceramic capacitor 1. The thickness of each of the first Ni plating layer 61A, the first Sn plating layer 62A, the second Ni plating layer 61B, and the second Sn plating layer 62B is preferably 2 μm or more and 15 μm or less.

[0059] The first external electrode 40A and the second external electrode 40B of this embodiment may have a conductive resin layer containing, for example, conductive particles and a thermosetting resin. When a conductive resin layer is provided as the base electrode layer (first base electrode layer 50A, second base electrode layer 50B), the conductive resin layer may be disposed so as to cover the baked layer, or may be disposed directly on the laminate 10 without providing a baked layer. When the conductive resin layer is disposed so as to cover the baked layer, the conductive resin layer is disposed between the baked layer and the plating layer (first plating layer 60A, second plating layer 60B). The conductive resin layer may completely cover the baked layer, or may cover only a portion of the baked layer.

[0060] The conductive resin layer containing a thermosetting resin is more flexible than a conductive layer made of, for example, a plating film or a fired conductive paste. Therefore, even if the multilayer ceramic capacitor 1 is subjected to a physical shock or a shock due to a thermal cycle, the conductive resin layer functions as a buffer layer. Therefore, the conductive resin layer suppresses the occurrence of cracks in the multilayer ceramic capacitor 1.

[0061] The metal constituting the conductive particles may be Ag, Cu, Ni, Sn, Bi, or an alloy containing any of these. The conductive particles preferably contain Ag. The conductive particles may be, for example, Ag metal powder. Ag has the lowest resistivity among metals, making it suitable as an electrode material. Furthermore, Ag is a noble metal, so it is resistant to oxidation and has high weather resistance. Therefore, Ag metal powder is suitable as the conductive particles.

[0062] The conductive particles may also be metal powder whose surface is coated with Ag. When using metal powder whose surface is coated with Ag, the metal powder is preferably Cu, Ni, Sn, Bi, or an alloy powder thereof. In order to maintain the properties of Ag while making the base metal inexpensive, it is preferable to use Ag-coated metal powder.

[0063] Furthermore, the conductive particles may be Cu or Ni that has been subjected to an anti-oxidation treatment. Furthermore, the conductive particles may be metal powder whose surface is coated with Sn, Ni, or Cu. When using metal powder whose surface is coated with Sn, Ni, or Cu, the metal powder is preferably Ag, Cu, Ni, Sn, Bi, or an alloy powder thereof.

[0064] The shape of the conductive particles is not particularly limited. The conductive particles may be spherical, flat, or the like, but it is preferable to use a mixture of spherical metal powder and flat metal powder.

[0065] The conductive particles contained in the conductive resin layer mainly play a role in ensuring the electrical conductivity of the conductive resin layer. Specifically, the contact between the conductive particles forms an electrical path within the conductive resin layer.

[0066] The resin constituting the conductive resin layer may include at least one selected from various known thermosetting resins, such as epoxy resin, phenolic resin, urethane resin, silicone resin, and polyimide resin. Among these, epoxy resin, which has excellent heat resistance, moisture resistance, and adhesion, is one of the most suitable resins. Furthermore, the resin of the conductive resin layer preferably includes a curing agent in addition to the thermosetting resin. When an epoxy resin is used as the base resin, the curing agent for the epoxy resin may be any of various known compounds, such as phenolic, amine, acid anhydride, imidazole, active ester, and amide-imide compounds.

[0067] The conductive resin layer may be formed of multiple layers. The thickness of the thickest part of the conductive resin layer is preferably 10 μm or more and 150 μm or less.

[0068] Note that a configuration may also be adopted in which a first plating layer 60A and a second plating layer 60B, which will be described later, are disposed directly on the laminate 10 without providing the first base electrode layer 50A and the second base electrode layer 50B. That is, the multilayer ceramic capacitor 1 may also be configured to include plating layers that are directly and electrically connected to the first internal electrode layer 31 and the second internal electrode layer 32. In such a case, a catalyst may be disposed on the surface of the laminate 10 as a pretreatment, and then the plating layers may be formed.

[0069] Even in this case, the plating layer preferably comprises multiple layers. The lower plating layer and the upper plating layer each preferably contain at least one metal selected from, for example, Cu, Ni, Sn, Pb, Au, Ag, Pd, Bi, or Zn, or an alloy containing these metals. The lower plating layer is more preferably formed using Ni, which has solder barrier properties. The upper plating layer is more preferably formed using Sn or Au, which have good solder wettability. For example, when the first internal electrode layer 31 and the second internal electrode layer 32 are formed using Ni, the lower plating layer is preferably formed using Cu, which has good bonding properties with Ni. The upper plating layer may be formed as needed, and the external electrode 40 may be composed of only the lower plating layer. Furthermore, the upper plating layer may be the outermost layer, or another plating layer may be formed on the surface of the upper plating layer.

[0070] The thickness of each plating layer, which is disposed without a base electrode layer, is preferably 1 μm or more and 15 μm or less. The plating layer preferably does not contain glass. The metal content per unit volume of the plating layer is preferably 99% by volume or more.

[0071] Note that when the plating layer is formed directly on the laminate 10, the thickness of the base electrode layer can be reduced. Therefore, the dimension of the multilayer ceramic capacitor 1 in the height direction T can be reduced by the amount of the reduced thickness of the base electrode layer, thereby making it possible to reduce the height of the multilayer ceramic capacitor 1. Alternatively, the thickness of the dielectric layer 20 sandwiched between the first internal electrode layer 31 and the second internal electrode layer 32 can be increased by the amount of the reduced thickness of the base electrode layer, thereby improving the thickness of the element body. In this way, by forming the plating layer directly on the laminate 10, the degree of freedom in designing the multilayer ceramic capacitor can be improved.

[0072] If the lengthwise dimension of the multilayer ceramic capacitor 1 including the laminate 10 and the external electrodes 40 is defined as L, then the L dimension is preferably 0.2 mm or more and 3.6 mm or less. If the heightwise dimension of the multilayer ceramic capacitor 1 is defined as T, then the T dimension is preferably 0.1 mm or more and 2.6 mm or less. If the widthwise dimension of the multilayer ceramic capacitor 1 is defined as W, then the W dimension is preferably 0.1 mm or more and 2.6 mm or less.

[0073] Next, the effective layer portion 11E will be described in detail. As shown in Fig. 3, the effective layer portion 11E includes a first side surface edge 11ES1 and a second side surface edge 11ES2. The first side surface edge 11ES1 extends in the height direction T on the first side surface WS1 side along the ends of the multiple internal electrode layers 30 on the first side surface WS1 side. The second side surface edge 11ES2 extends in the height direction T on the second side surface WS2 side along the ends of the multiple internal electrode layers 30 on the second side surface WS2 side.

[0074] The effective layer 11E includes a first side surface side effective layer 11E1, a second side surface side effective layer 11E2, and a central side effective layer 11EC. The first side surface side effective layer 11E1 is a region of the effective layer 11E extending from the first side surface side edge 11ES1 toward the inside of the effective layer 11E in the width direction W. The second side surface side effective layer 11E2 is a region of the effective layer 11E extending from the second side surface side edge 11ES2 toward the inside of the effective layer 11E in the width direction W. The central side effective layer 11EC is a region of the effective layer 11E near the center in the width direction W.

[0075] Here, among the plurality of dielectric layers 20, the thickness in the height direction T of the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is thinner than the thickness in the height direction T of the dielectric layer 20 present inside the center side effective layer portion 11EC. In other words, the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 (hereinafter collectively referred to as side surface side effective layer portions) are portions in which the thickness in the height direction T of the dielectric layer 20 present inside them is thinner than the thickness in the height direction T of the dielectric layer 20 present inside the center side effective layer portion 11EC.

[0076] The thickness of the dielectric layer 20 in the height direction T, in the first side surface side effective layer portion 11E1, continuously decreases from the boundary with the central portion side effective layer portion 11EC toward the first side surface side edge 11ES1 in the width direction W. The thickness of the dielectric layer 20 in the height direction T, in the second side surface side effective layer portion 11E2, continuously decreases from the boundary with the central portion side effective layer portion 11EC toward the second side surface side edge 11ES2 in the width direction W. The region where the thickness of the dielectric layer 20 in the height direction T continuously decreases is preferably located within the width direction W of the effective layer portion 11E from the first side surface side edge 11ES1 and the second side surface side edge 11ES2 by a dimension of 1% to 17% of the dimension of the width direction W of the effective layer portion 11E.

[0077] This allows the dielectric layers, internal electrodes, and side surface outer layer portions near the side surface effective layer portions to be appropriately compressed, thereby increasing the density of the side surface effective layer portions. This makes it possible to suppress the penetration of moisture into the laminate 10. As a result, the moisture resistance reliability of the multilayer ceramic capacitor 1 can be improved.

[0078] The dimension in the width direction W of the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is preferably 1% to 17% of the dimension in the width direction W of the effective layer portion 11E. It is more preferable that the dimension in the width direction W of the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is 1% to 6% of the dimension in the width direction W of the effective layer portion 11E.

[0079] Within the above range, it is possible to appropriately ensure a thin range for the dielectric layer, and to ensure moisture resistance reliability.

[0080] The particle diameter of the ceramic material in the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is larger than the particle diameter of the ceramic material in the dielectric layer present inside the center side effective layer portion 11EC.

[0081] The ratio of the minimum thickness in the height direction T of the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 to the maximum particle diameter of the ceramic material in the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is preferably 0.83 or more and 1.82 or less. The maximum particle diameter is a value calculated by the "average value + 3σ" of the particle diameters of multiple ceramic particles measured by the method described below. The minimum thickness is a value calculated by the "average value - 3σ" of the thickness of the dielectric layer 20 measured by the method described below.

[0082] The above configuration ensures an appropriate number of particles in each dielectric layer 20 in the side surface effective layer portion, and further uniformizes the electric field distribution in the side surface effective layer portion, thereby further improving high-temperature reliability.

[0083] If the ratio of the maximum particle diameter of the ceramic material in the dielectric layer 20 present inside the side surface-side effective layer to the minimum thickness in the height direction T of the dielectric layer 20 present inside the side surface-side effective layer is 0.83 or less, the number of particles in one dielectric layer 20 in the side surface-side effective layer cannot be secured, the electric field distribution in the side surface-side effective layer becomes non-uniform, and high-temperature reliability may decrease. Furthermore, if the above ratio is 1.82 or more, the thickness of the dielectric layer must be increased, which reduces the capacitance accordingly.

[0084] <Method for measuring particle size and dielectric layer thickness> The following describes a method for measuring the particle size and the thickness of the dielectric layer 20 in this embodiment. The particle size of the ceramic particles of the ceramic material in the dielectric layer 20 and the thickness of the dielectric layer 20 are measured based on observation with an SEM (scanning electron microscope).

[0085] First, the measurement locations will be described. SEM observation for the measurement is performed on a WT cross section that is approximately parallel to the first end face LS1 and the second end face LS2 and is located approximately at the center in the length direction L of the effective layer 11E. SEM observation of the central effective layer 11EC is performed at position P1 on the WT cross section shown in FIG. 3, more specifically, at the center in the height direction T and the center in the width direction W of the effective layer 11E. SEM observation of the first side surface side effective layer 11E1 and the second side surface side effective layer 11E2 is performed at positions P2A and P2B on the WT cross section shown in FIG. 3, more specifically, at the center in the height direction T and the center in the width direction W of the first side surface side effective layer 11E1 and the second side surface side effective layer 11E2.

[0086] The method for measuring the average particle size and maximum particle size of a ceramic material is described below. The laminate 10 is fractured with nippers at approximately the center in the longitudinal direction L so that the WT cross section is exposed. The fractured surface is then heat-treated at 1000°C for 30 minutes, pre-treating the particle size to make it easier to observe. After processing using the above method, the measurement area is photographed at a high magnification of 20,000x using an FE-SEM. The particle diameters are measured by tracing the outer edges of the particles on the captured image using analysis software, and the average value is calculated. This is the average particle size. The maximum particle size is calculated as the "average value + 3σ" of the measured values. For the center-side effective layer 11EC, these values ​​are calculated using image data at the measurement location P1 described above. For the first side-side effective layer 11E1 and the second side-side effective layer 11E2 (side-side effective layer), these values ​​are calculated using two image data at the measurement locations P2A and P2B described above.

[0087] The method for measuring the average thickness and minimum thickness of the dielectric layer 20 in the height direction T will be described. The laminate 10 is hardened with resin and polished so that the WT cross section substantially parallel to the first end face LS1 and the second end face LS2 is exposed. Then, the measurement location on the polished WT cross section of the laminate 10 is photographed at 5000x magnification using an SEM.

[0088] The thicknesses of the 10 dielectric layers 20 (cross sections of the 10 dielectric layers 20) and the 10 internal electrode layers 30 (cross sections of the 10 internal electrode layers 30) on the captured image are measured and the average values ​​are calculated.

[0089] The method for measuring the thickness of the dielectric layer 20 will be described in detail below with reference to Fig. 5. The method for measuring the thickness of the dielectric layer 20 at the measurement points P1, P2A, and P2B is the same, so only the measurement at P1 will be described as a representative example. Here, the case where the thickness of the internal electrode layer 30 is measured in addition to the thickness of the dielectric layer 20 will be described.

[0090] The thickness of the internal electrode layer 30 is measured as follows. Fig. 5 is an example of an enlarged image of the cross section of the exposed effective layer portion at the position of the measurement target point P1. In the illustrated enlarged image, for example, a plurality of straight lines La, Lb, Lc, Ld, and Le extending in the height direction T (stacking direction T) are drawn at approximately equal pitch intervals S. The pitch S is preferably about 5 to 10 times the thickness of the internal electrode layer 30 to be measured, and for example, when measuring an internal electrode layer 30 with a thickness of about 1 µm, the pitch S is set to 5 µm.

[0091] Next, the thicknesses d1, d2, d3, d4, and d5 of the internal electrode layer 30 are measured on each of the five straight lines La, Lb, Lc, Ld, and Le, and the average value is defined as the thickness in the height direction T of one internal electrode layer 30. However, if an internal electrode layer 30 is missing on the straight lines La, Lb, Lc, Ld, and Le, and the dielectric layers 20 sandwiching this internal electrode layer 30 are connected to each other, or if the enlarged view of the measurement position is unclear, a new straight line is drawn and the thickness of the internal electrode layer 30 is measured. This operation is performed for 10 internal electrode layers 30, and the average value is defined as the average thickness in the height direction T of the internal electrode layer 30 in this embodiment.

[0092] The thickness of the dielectric layer 20 is measured in the same manner as the internal electrode layer 30. The thicknesses D1, D2, D3, D4, and D5 of the dielectric layer 20 are measured along each of the five straight lines La, Lb, Lc, Ld, and Le, and the average value is used as the thickness of one dielectric layer 20. This procedure is performed for ten dielectric layers 20, and the average value is used as the average thickness of the dielectric layer 20 in the height direction T of this embodiment. The minimum thickness of the dielectric layer 20 in the height direction T is calculated by subtracting 3σ from the average value. For the center-side effective layer portion 11EC, these values ​​are calculated using the thickness data of the ten dielectric layers at the measurement point P1 described above. For the first side-side effective layer portion 11E1 and the second side-side effective layer portion 11E2 (side-side effective layer portions), these values ​​are calculated using the thickness data of a total of 20 dielectric layers at the measurement points P2A and P2B described above.

[0093] Next, a method for manufacturing the multilayer ceramic capacitor 1 of this embodiment will be described.

[0094] A dielectric sheet for the dielectric layer 20 and a conductive paste for the internal electrode layer 30 are prepared. The dielectric sheet and the conductive paste for the internal electrode contain a binder and a solvent. The binder and the solvent may be known.

[0095] On the dielectric sheets, a conductive paste for the internal electrode layers 30 is printed in a predetermined pattern by, for example, screen printing or gravure printing. In this way, a dielectric sheet on which the pattern of the first internal electrode layer 31 is formed and a dielectric sheet on which the pattern of the second internal electrode layer 32 is formed are prepared.

[0096] A predetermined number of dielectric sheets on which the pattern of the internal electrode layer is not printed are stacked to form a portion that will become the first main surface-side outer layer portion 12 on the first main surface TS1 side. A dielectric sheet on which the pattern of the first internal electrode layer 31 and a dielectric sheet on which the pattern of the second internal electrode layer 32 are printed are stacked in this order on top of that to form a portion that will become the internal layer portion 11. A predetermined number of dielectric sheets on which the pattern of the internal electrode layer is not printed are stacked on top of this portion that will become the second main surface-side outer layer portion 13 on the second main surface TS2 side. In this way, a laminated sheet is produced.

[0097] The laminated sheet is pressed in the height direction T by means of an isostatic press or the like to produce a laminated block. In this embodiment, the thickness of the dielectric layer 20 on the side surface side is made relatively thin. For example, the thickness and hardness of the rubber used for the isostatic press are adjusted to achieve the configuration of the present application. Specifically, the thickness of the rubber used for the isostatic press is increased. Alternatively, the hardness of the rubber used for the isostatic press is made harder than usual. This makes the thickness of the dielectric layer 20 on the side surface side relatively thin.

[0098] The laminated block is cut to a predetermined size to obtain laminated chips, and at this time, corners and ridges of the laminated chips may be rounded by barrel polishing or the like.

[0099] The process of firing a laminated chip consists of a calcination process and a firing process. In the calcination process, the laminated chip is first placed on a firing setter and the binder contained in the laminated chip is heated and removed. This process removes the organic binder contained in the ceramic green sheets used as the dielectric sheets of the laminated chip and the conductive paste for the internal electrode layers 30. The calcination process is performed in an air atmosphere in the furnace, but the amount of gas such as N2, H2, or H2O may be adjusted. The calcination temperature is preferably between 150°C and 400°C.

[0100] Next, in the firing process, the laminated chips placed on the firing setter after pre-firing are placed in a firing furnace, and the temperature inside the furnace is set to 600°C or higher and 1400°C or lower, and firing is performed. The temperature rise rate here is 1°C / min to 6000°C / min, and the particle size is adjusted. The amount of gas such as N2, H2, and H2O in the furnace is adjusted. This allows the laminate to be obtained.

[0101] In this embodiment, the laminated chip is fired to produce the laminate 10, and the laminated chip is fired in a reducing atmosphere to relatively increase the grain size on the side surface. For example, the oxygen partial pressure during firing is adjusted to achieve the configuration of the present application. Specifically, firing is performed in an atmosphere with a lower oxygen partial pressure than normal. This causes the grain size on the side surface, which is in direct contact with the atmosphere with the lowered oxygen partial pressure, to become relatively large.

[0102] A conductive paste that will become the base electrode layers (first base electrode layer 50A, second base electrode layer 50B) is applied to both end surfaces of the laminate 10. Thereafter, a baking process is performed to form the base electrode layers. In this embodiment, the base electrode layers are baked layers. A conductive paste containing a glass component and a metal is applied to the laminate 10 by a method such as dipping. Thereafter, a baking process is performed to form the base electrode layers. The baking temperature at this time is preferably 700°C or higher and 900°C or lower. Furthermore, when the base electrode layers are formed as baked layers, the baked layer may contain a ceramic component. In this case, the ceramic component may be contained instead of the glass component, or both may be contained.

[0103] In this case, it is particularly preferable to use the same type of ceramic material as that of the dielectric layer 20 as the ceramic material to be added. In this case, it is preferable to apply a conductive paste to the laminated chip before firing, and then simultaneously fire the laminated chip and the conductive paste applied to the laminated chip to form the laminated body 10 on which a fired layer is formed. The temperature of the firing process (firing temperature) at this time is preferably 900°C or higher and 1400°C or lower.

[0104] Thereafter, a plating layer is formed on the surface of the base electrode layer. In this embodiment, a first plating layer 60A is formed on the surface of the first base electrode layer 50A. Furthermore, a second plating layer 60B is formed on the surface of the second base electrode layer 50B. In this embodiment, a Ni plating layer and an Sn plating layer are formed as the plating layers. Either electrolytic plating or electroless plating may be used for the plating process. However, electroless plating has the disadvantage of requiring pretreatment using a catalyst or the like to improve the plating deposition rate, which complicates the process. Therefore, it is usually preferable to use electrolytic plating. The Ni plating layer and the Sn plating layer are formed sequentially, for example, by barrel plating.

[0105] When the base electrode layer is formed as a thin film layer, the thin film layer is formed as the base electrode layer in the area where the external electrode is to be formed by masking or the like. The thin film layer is formed by a thin film formation method such as sputtering or vapor deposition. The thin film layer is a layer of metal particles deposited to a thickness of 1.0 μm or less.

[0106] When a conductive resin layer is provided as the base electrode layer, the conductive resin layer may be disposed so as to cover the baking layer, or may be disposed directly on the laminate 10 without providing a baking layer. When providing a conductive resin layer, a conductive resin paste containing a thermosetting resin and a metal component is applied to the baking layer or the laminate 10, and then heat-treated at a temperature of 250°C to 550°C or higher. This causes the thermosetting resin to thermally harden, forming a conductive resin layer. The atmosphere during this heat treatment is preferably an N2 atmosphere. Furthermore, to prevent the resin from scattering and the various metal components from oxidizing, the oxygen concentration is preferably 100 ppm or less.

[0107] Alternatively, the plating layer may be disposed directly on the exposed portion of the internal electrode layer 30 of the laminate 10 without providing a base electrode layer. In this case, the first end face LS1 and the second end face LS2 of the laminate 10 are plated, and the plating layer is formed on the exposed portion of the internal electrode layer 30. Either electrolytic plating or electroless plating may be used for the plating process. However, electroless plating has the disadvantage of requiring pretreatment using a catalyst or the like to improve the plating deposition rate, which complicates the process. Therefore, electrolytic plating is usually preferred. Barrel plating is preferred as the plating method. Furthermore, if necessary, the upper plating layer formed on the surface of the lower plating layer may be formed by the same method as the lower plating layer.

[0108] Through these manufacturing steps, the multilayer ceramic capacitor 1 is manufactured.

[0109] <Example> Using the manufacturing method according to the above embodiment, a multilayer ceramic capacitor was fabricated as a sample of the example. In fabricating the sample of the example, the thickness of the rubber used in the isostatic press was adjusted. Specifically, a rubber thicker than usual was used. In addition, in fabricating the sample of the example, the oxygen partial pressure during firing was adjusted. Specifically, firing was performed in an atmosphere with a lower oxygen partial pressure than usual. The specifications of the multilayer ceramic capacitor are as follows: Dimensions of the multilayer ceramic capacitor: 1.68mm (length L) x 0.87mm (width W) x 0.88mm (thickness T) Ceramic material: SrBaZrO3 Capacitance: 100nF Internal electrode material: Ni

[0110] Using the manufacturing method according to the above embodiment, multilayer ceramic capacitors having the following specifications were fabricated as comparative samples under the following conditions. The specifications of the multilayer ceramic capacitors of Comparative Examples 1 and 2 are as follows: Comparative Example 1: A rubber having a thickness thinner than usual was used. The firing was carried out in an atmosphere with a higher oxygen partial pressure than usual. Comparative Example 2: A rubber having a thickness thinner than usual was used. The firing was carried out in an atmosphere with a lower oxygen partial pressure than usual. Dimensions of the multilayer ceramic capacitor: 1.68mm (length L) x 0.87mm (width W) x 0.88mm (thickness T) Ceramic material: SrBaZrO3 Capacitance: 100nF ·Internal electrode: Ni

[0111] Next, the samples of the examples and comparative examples were subjected to a moisture resistance reliability test and a high-temperature reliability test. Furthermore, the particle size of the ceramic material in the dielectric layer and the thickness of the dielectric layer were measured for 10 samples produced in the same lot using the above-mentioned measurement method. The measured values ​​of the particle size and thickness are the average values ​​of the 10 samples.

[0112] As a moisture resistance reliability test, a moisture resistance test was conducted on each sample based on the PCBT test method. More specifically, each sample was mounted on a wiring board using eutectic solder, placed in a high-temperature, high-humidity chamber at a temperature of 125°C and a relative humidity of 95%RH, and a direct current of 25V was applied between a pair of external electrodes. This condition was maintained for 72 hours. A sample with no decrease in insulation resistance value of two digits or more before and after the test was evaluated as "Good," and a sample with 20 or more decreases in insulation resistance value of two digits or more before and after the test was evaluated as "Poor." Thirty-six samples were tested for each example and comparative example.

[0113] As a high-temperature reliability test, a high-temperature load test based on the HALT test method was conducted on each sample. More specifically, each sample was individually set in a dedicated jig, placed in a high-temperature chamber at a temperature of 150°C, and a direct current of 100V was applied between a pair of external electrodes. This condition was maintained for 100 hours. Samples that did not fail during the test were evaluated as "Good," samples that failed 1 to 5 times during the test were evaluated as "Good," and samples that failed 6 or more times during the test were evaluated as "Poor." Thirty-six samples were tested for each example and comparative example.

[0114] Below are summarized the measurement data for the thickness of the dielectric layer and the particle size of the ceramic material in the dielectric layer, as well as the results of the moisture resistance reliability test and the high temperature reliability test for the samples of each example and each comparative example. [Table 1]

[0115] From the above results, Examples 1 to 5, which are samples in which the average thickness A in the height direction T of the dielectric layer present inside the side-side effective layer portion is thinner than the average thickness B in the height direction T of the dielectric layer present inside the center-side effective layer portion, showed good results in the moisture resistance reliability test. On the other hand, Comparative Examples 1 and 2, which are samples in which the average thickness A in the height direction T of the dielectric layer present inside the side-side effective layer portion is thicker than the average thickness B in the height direction T of the dielectric layer present inside the center-side effective layer portion, showed poor results in the moisture resistance reliability test.

[0116] Furthermore, Examples 1 to 5, which are samples in which the average particle diameter C of the ceramic material in the dielectric layer present inside the side effective layer portion is larger than the average particle diameter D of the ceramic material in the dielectric layer present inside the center effective layer portion, showed good results in the high-temperature reliability test. On the other hand, Comparative Example 1, which is a large sample in which the average particle diameter C of the ceramic material in the dielectric layer present inside the side effective layer portion is smaller than the average particle diameter D of the ceramic material in the dielectric layer present inside the center effective layer portion, showed poor results in the high-temperature reliability test.

[0117] Furthermore, Examples 2 to 5, which are samples in which the ratio E / F of the minimum thickness E in the height direction T of the dielectric layer present inside the side effective layer portion to the maximum particle diameter F of the ceramic material in the dielectric layer present inside the side effective layer portion is 0.83 or more and 1.82 or less, showed even better results in high-temperature reliability tests than Example 1, which is a sample outside that range.

[0118] From the above, it can be seen that it is possible to improve both moisture resistance and high-temperature reliability by making the average thickness in the height direction T of the dielectric layer present inside the side-side effective layer portion thinner than the average thickness in the height direction T of the dielectric layer present inside the center-side effective layer portion and making the average particle diameter of the ceramic material in the dielectric layer present inside the side-side effective layer portion larger than the average particle diameter of the ceramic material of the dielectric layer present inside the center-side effective layer portion.

[0119] From the above results, the multilayer ceramic capacitor 1 of this embodiment has the following advantages.

[0120] (1) The multilayer ceramic capacitor 1 of this embodiment includes a laminate 10 including a plurality of laminated dielectric layers 20 and a plurality of laminated internal electrode layers 30, a first main surface TS1 and a second main surface TS2 facing each other in a height direction T, a first side surface WS1 and a second side surface WS2 facing each other in a width direction W perpendicular to the height direction T, and a first end surface LS1 and a second end surface LS2 facing each other in a length direction L perpendicular to the height direction T and the width direction W, and the multilayer ceramic capacitor 1 has an effective layer portion 11E in which the plurality of internal electrode layers 30 face each other in the height direction T via the dielectric layer 20, the multilayer ceramic capacitor 1 having the laminate 10, the effective layer portion 11E including a first side edge 11ES1 extending in the height direction T on the first side surface WS1 side and a second side edge 11ES2 extending in the height direction T on the second side surface WS2 side, The dielectric layer 11E comprises a first side surface side effective layer portion 11E1 including a region extending from the side 11ES1 toward the inside of the effective layer portion 11E in the width direction W, a second side surface side effective layer portion 11E2 including a region extending from the second side surface side edge 11ES2 toward the inside of the effective layer portion 11E in the width direction W, and a central side effective layer portion 11EC including a region near the center of the effective layer portion 11E in the width direction W, characterized in that the average thickness in the height direction T of the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is thinner than the average thickness in the height direction T of the dielectric layer 20 present inside the central side effective layer portion 11EC, and the average particle diameter of the ceramic material in the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is larger than the average particle diameter of the ceramic material of the dielectric layer 20 present inside the central side effective layer portion 11EC.

[0121] Multilayer ceramic capacitors have been known for some time. Generally, multilayer ceramic capacitors include a ceramic sintered body made of a dielectric ceramic such as barium titanate. A plurality of internal electrodes are arranged inside the ceramic sintered body so as to overlap each other with ceramic layers interposed therebetween. External electrodes are also formed on one end surface and the other end surface of the ceramic sintered body so as to be electrically connected to the internal electrodes.

[0122] In such a multilayer ceramic capacitor, if the thickness in the height direction T of the dielectric layer inside the side effective layer portion is thicker than the thickness in the height direction T of the dielectric layer inside the central effective layer portion, it will not be compressed properly, and a large number of pores (air bubbles) will be present in the side effective layer portion, which will reduce the density of the dielectric layer inside the side effective layer portion and reduce the moisture resistance reliability.

[0123] In this embodiment, as described above, the thickness in the height direction T of the dielectric layers present inside the side effective layer portions is made thinner than the thickness in the height direction T of the dielectric layers present inside the center effective layer portions. This improves the density of the side effective layer portions and suppresses moisture penetration into the laminate. As a result, the moisture resistance reliability of the multilayer ceramic capacitor can be improved.

[0124] In addition, in this embodiment, the particle diameter of the ceramic material in the dielectric layer present inside the side effective layer portion is larger than the particle diameter of the ceramic material in the dielectric layer present inside the center effective layer portion.

[0125] It is believed that increasing the particle size can suppress the occurrence of additive segregation phases. This is because increasing the particle size reduces the number of grain boundaries, which is thought to suppress the occurrence of additive segregation phases in the low-resistivity layer, which tend to segregate at grain boundaries. As a result, it is thought that electric field concentration can be suppressed, leading to improved high-temperature reliability.

[0126] As described above, by controlling the thickness of the dielectric layer and the ceramic particle diameter, it is possible to improve the density of the side effective layer portion and thereby improve moisture resistance, while at the same time optimizing the number of ceramic particles in one dielectric layer and dispersing the electric field within one dielectric layer, thereby improving high-temperature reliability.

[0127] Therefore, the present invention can provide a multilayer ceramic capacitor that can improve both moisture resistance and high-temperature reliability by controlling the thickness of the region where the dielectric element is thin and the ceramic particle size.

[0128] (2) This embodiment is characterized in that the ratio of the maximum particle diameter of the ceramic material in the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 to the minimum thickness in the height direction T of the dielectric layer 20 present inside the first side surface side effective layer portion 11E1 and the second side surface side effective layer portion 11E2 is 0.83 or more and 1.82 or less. This ensures an appropriate number of particles in one dielectric layer in the side surface side effective layer portion, thereby further uniforming the electric field distribution within the layer of the side surface side effective layer portion. As a result, high-temperature reliability can be further improved.

[0129] (3) In this embodiment, the ceramic material in the dielectric layer 20 is characterized by having a perovskite structure containing Ba, Sr, Zr, Ti, Hf, and Si, and optionally containing Ca. This allows the dielectric layer 20 to be thinned, and even with this thinning, it is possible to obtain excellent insulation degradation life and humidity load resistance life in a high electric field.

[0130] [Variations] For example, the configuration of the multilayer ceramic capacitor 1 is not limited to the configurations shown in Figures 1 to 4. For example, the multilayer ceramic capacitor 1 may be a multilayer ceramic capacitor with a double structure as shown in Figure 6.

[0131] The multilayer ceramic capacitor 1 shown in FIG. 6 is a double-structure multilayer ceramic capacitor 1, and includes, as the internal electrode layers 30, first internal electrode layers 33 and second internal electrode layers 34, as well as floating internal electrode layers 35 that are not extended to either the first end face LS1 or the second end face LS2. By providing the floating internal electrode layers 35 as the internal electrode layers 30 in this way, the multilayer ceramic capacitor 1 has a structure in which the effective layer portion is divided into multiple parts. As a result, multiple capacitor components are formed between the opposing internal electrode layers 30, and these capacitor components are connected in series. Therefore, the voltage applied to each capacitor component is reduced, and the multilayer ceramic capacitor 1 can have a high withstand voltage.

[0132] The present invention is not limited to the configurations of the above-described embodiments, and can be appropriately modified and applied within the scope of the present invention. Note that the present invention also includes a combination of two or more of the individual desirable configurations described in the above-described embodiments. [Explanation of symbols]

[0133] 1. Multilayer ceramic capacitors T Height direction W width direction L lengthwise TS1 First principal surface TS2 Second principal surface WS1 First Aspect WS2 Second Aspect LS1 First end face LS2 Second end face 10 Laminate 11E Effective layer 11EC Central effective layer 11E1 First side surface side effective layer portion 11E2 second side effective layer portion 11ES1 First lateral edge 11ES2 Second lateral edge 20 dielectric layer 30 Internal electrode layer

Claims

1. a plurality of dielectric layers stacked one upon the other and a plurality of internal electrode layers stacked one upon the other; a first main surface and a second main surface facing each other in a height direction; a first side surface and a second side surface facing each other in a width direction perpendicular to the height direction; a first end surface and a second end surface facing each other in a length direction perpendicular to the height direction and the width direction; a multilayer ceramic capacitor having a laminate in which effective layer portions are formed in which the plurality of internal electrode layers face each other in a height direction via the dielectric layer, the dielectric layer comprises a ceramic material; The effective layer portion is a first side edge extending in a height direction of the first side surface; a second side edge extending in a height direction of the second side, a first side surface effective layer portion including a region extending from the first side surface edge toward the inside of the effective layer portion in a width direction; a second side surface effective layer portion including a region extending from the second side surface edge toward the inside of the effective layer portion in the width direction; a central effective layer portion including a region near the central portion of the effective layer portion in the width direction, the average thickness in the height direction of the dielectric layer present inside the first side surface side effective layer portion and the second side surface side effective layer portion is smaller than the average thickness in the height direction of the dielectric layer present inside the central portion side effective layer portion, A multilayer ceramic capacitor, wherein the average particle diameter of the ceramic material in the dielectric layer present inside the first side effective layer portion and the second side effective layer portion is larger than the average particle diameter of the ceramic material in the dielectric layer present inside the center effective layer portion.

2. With respect to the maximum particle diameter of the ceramic material in the dielectric layer present inside the first side effective layer portion and the second side effective layer portion, 2. The multilayer ceramic capacitor according to claim 1, wherein the ratio of the minimum height thickness of the dielectric layer present within the first side surface side effective layer portion and the second side surface side effective layer portion is 0.83 or more and 1.82 or less.

3. 3. The multilayer ceramic capacitor according to claim 1, wherein the ceramic material in the dielectric layers has a perovskite structure containing Ba, Sr, Zr, Ti, Hf, and Si, and optionally containing Ca.

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