Al/Mn Alloy Internal Electrodes for Ceramic Components
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Solution Overview
Problem
Laminated ceramic electronic components with base metal internal electrodes face issues such as delamination due to stress from firing processes and require complex re-oxidation treatments in nitrogen atmospheres, limiting material design and corrosion resistance.
Innovation Solution
Incorporating an Al/Mn alloy with an Al/Mn ratio of 80/20 or more as internal electrodes, allowing firing in air and forming a protective Al2O3 layer to reduce stress and enhance corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If base metal internal electrodes are used to reduce cost, then manufacturing cost is reduced, but delamination occurs due to stress during firing
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the internal electrode material. Specifically, it uses an Al-Mn-Si alloy with controlled composition ranges (Al: 70-95 wt%, Mn: 3-20 wt%, Si: 0.1-5 wt%) to achieve both cost reduction and delamination resistance. The specific compositional parameters optimize the balance between manufacturing cost and stress resistance during firing.
Solution Approach 2:
The patent employs composite materials by creating a multi-element Al-Mn-Si alloy system rather than using pure base metals. This composite alloy structure combines the advantages of different elements: Al provides cost reduction and conductivity, Mn improves strength and stress resistance, and Si enhances oxidation resistance. The synergistic effect of these elements resolves the contradiction between cost and reliability.
2Ease of manufacture
If base metal internal electrodes are used to reduce cost, then manufacturing cost is reduced, but corrosion resistance deteriorates in high-temperature high-humidity environments
Solution Approach 1:
The patent uses parameter changes by optimizing the chemical composition parameters of the Al-Mn-Si alloy. The specific ranges (Al: 70-95 wt%, Mn: 3-20 wt%, Si: 0.1-5 wt%) are designed to provide both cost effectiveness and enhanced corrosion resistance. The controlled addition of Mn and Si elements specifically addresses the corrosion resistance issue while maintaining cost benefits.
Solution Approach 2:
The composite Al-Mn-Si alloy material provides improved corrosion resistance through the synergistic effects of its components. Mn forms protective oxide layers that prevent corrosion in high-temperature high-humidity environments, while Si enhances oxidation resistance. This composite material structure maintains the cost advantage of base metals while achieving the required reliability.
3Reliability
If nitrogen atmosphere firing is used to prevent oxidation, then oxidation resistance is improved, but process complexity increases due to re-oxidation treatment
Solution Approach 1:
The patent applies self-service by designing an alloy composition that inherently provides oxidation resistance during firing. The Si and Mn elements in the Al-Mn-Si alloy form protective oxide layers on the surface during air firing, eliminating the need for complex nitrogen atmosphere control and subsequent re-oxidation treatments. The material itself provides the oxidation protection it needs.
Solution Approach 2:
The patent changes the compositional parameters of the internal electrode material to include oxidation-resistant elements (Si: 0.1-5 wt%, Mn: 3-20 wt%). This compositional modification enables the material to withstand oxidation during air firing, thereby simplifying the firing process from complex nitrogen atmosphere control to simple air firing without compromising oxidation resistance.
4Reliability
If Al-Mn-Si alloy with specific composition is used, then delamination is inhibited and corrosion resistance is improved, but material design freedom is constrained by composition ratios
Solution Approach 1:
The patent manages the balance between reliability and design freedom by establishing specific compositional parameter ranges rather than fixed values. The Al-Mn-Si alloy allows flexibility within ranges (Al: 70-95 wt%, Mn: 3-20 wt%, Si: 0.1-5 wt%), enabling material designers to optimize specific properties while maintaining the core benefits of delamination and corrosion resistance. This parametric approach provides controlled freedom within defined boundaries.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution inhibits delamination and improves corrosion resistance, enabling reliable operation in high-humidity environments and expanding material design freedom for ceramic components.
Implementation Method 1
forming a protective Al2O3 layer to reduce stress and enhance corrosion resistance
Implementation Method 2
a fixed amount of Mn is contained in the Al of the internal electrode to improve the corrosion resistance of the internal electrode
Data Source
AI summary
Provided is a laminated ceramic electronic component which has excellent mechanical characteristics, internal electrode corrosion resistance, high degree of freedom in ceramic material design, low cost, low defective rate, and various properties. The laminated ceramic electronic component includes: a laminate which has a plurality of laminated ceramic layers and Al/Mn alloy internal electrodes at a plurality of specific interfaces between the ceramic layers and an external electrode formed on the outer surface of the laminate, wherein the Al/Mn ratio of the Al/Mn alloy is 80/20 or more.