Al/Ti Alloy Internal Electrodes for Laminated 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 during firing, require a reducing atmosphere, and have limited design flexibility and corrosion resistance, especially in high-humidity environments.
Innovation Solution
A laminated ceramic electronic component with internal electrodes made of an Al/Ti alloy having a ratio of 91/9 or more, allowing firing in air and forming a protective Al2O3 layer for improved corrosion resistance and reduced stress, thereby preventing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If base metal internal electrodes are used, then cost is reduced, but delamination occurs due to stress during firing
Solution Approach 1:
The invention changes the chemical composition parameters of the internal electrode by using a base metal alloy containing 5-50 atom% of a specific metal element (Ni, Cu, Zn, or Co) combined with Al, rather than pure base metal. This compositional parameter change allows the electrode to withstand firing stress without delamination while maintaining cost-effectiveness.
Solution Approach 2:
The invention employs a composite base metal alloy material combining Al with another metal element (Ni, Cu, Zn, or Co) in specific proportions. This composite structure provides both the cost advantage of base metals and the stress resistance needed to prevent delamination during firing, resolving the contradiction between cost reduction and reliability.
2Reliability
If base metal internal electrodes are used, then cost is reduced, but corrosion resistance deteriorates in high-humidity environments
Solution Approach 1:
The invention modifies the material composition parameters by introducing a specific alloying element (Ni, Cu, Zn, or Co) at controlled concentrations (5-50 atom%) into the Al-based internal electrode. This parameter adjustment significantly improves corrosion resistance in high-humidity environments while maintaining the cost benefits of base metal usage.
3Ease of manufacture
If base metal internal electrodes are used, then cost is reduced, but firing atmosphere control becomes more difficult
Solution Approach 1:
The invention changes the chemical composition parameters of the internal electrode material to include Al combined with Ni, Cu, Zn, or Co in specific ratios. This compositional modification enables the electrode to resist oxidation during firing in air atmosphere, eliminating the need for complex reducing atmosphere control while maintaining manufacturing cost effectiveness.
4Reliability
If Al/Ti alloy with 91/9 ratio or more is used, then delamination is inhibited, but material composition flexibility is reduced
Solution Approach 1:
The invention establishes specific parameter ranges for the alloy composition (5-50 atom% of Ni, Cu, Zn, or Co with Al) that simultaneously achieve delamination resistance and maintain reasonable material design flexibility. This parameter optimization resolves the contradiction between reliability and adaptability.
Solution Approach 2:
The invention applies different metal elements (Ni, Cu, Zn, or Co) at different concentration levels within the alloy system, allowing optimization of specific properties while maintaining overall delamination resistance. This local quality approach enables tailored material designs for different application requirements within the established compositional framework.
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 enhances corrosion resistance, enabling reliable operation in high-humidity environments and offering design flexibility for ceramic materials, allowing for various properties and applications.
Implementation Method 1
forming a protective Al2O3 layer for improved corrosion resistance and reduced stress
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 internal electrodes formed along at a plurality of specific interface between the ceramic layers and having an Al/Ti alloy as a component; and an external electrode formed on the outer surface of the laminate. The Al/Ti ratio of the Al/Ti alloy is 91/9 or more.