BaTiO3 Dielectric Composition for Low-Temperature Copper Electrode Co-Sintering
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Solution Overview
Problem
Current dielectric ceramic compositions for laminated ceramic capacitors require high sintering temperatures and contain harmful substances like lead and bismuth, making them unsuitable for low-temperature processing with copper internal electrodes, which affects electrical conductivity and longevity under high-temperature loads.
Innovation Solution
A dielectric ceramic composition primarily composed of BaTiO3 with auxiliary components like Re, Mn, V, Mo, Cu, B, Li, and Sr, optimized to be sintered at 1030°C or below, allowing co-sintering with copper and achieving X7R or X5R characteristics, high insulation resistance, and extended longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dielectric ceramic compositions are used with high sintering temperatures (1150-1400°C), then sufficient dielectric characteristics and insulation resistance are achieved, but harmful substances like lead and bismuth are required in the composition and nickel must be used as electrode material which is expensive and rare
Solution Approach 1:
The patent changes the sintering temperature parameter from traditional high temperatures (1150-1400°C) to low temperatures (1030°C or below). This is achieved by modifying the dielectric ceramic composition to include specific amounts of auxiliary components (Re: 0.01-5 mol%, Mn: 0.1-5 mol%, V: 0.01-1 mol%, Mo: 0.01-1 mol%, Cu: 0.1-5 mol%, B: 0.1-5 mol%, Li: 0.1-5 mol%, Sr: 0.1-5 mol%, Ca: 0.1-5 mol%) that enable low-temperature sintering while maintaining dielectric characteristics and eliminating harmful substances like Pb and Bi
Solution Approach 2:
The patent uses a composite dielectric ceramic composition based on BaTiO3 primary component combined with multiple auxiliary components (Re, Mn, V, Mo, Cu, B, Li, Sr, Ca). This composite structure enables the material to achieve both low-temperature sinterability and sufficient dielectric characteristics without requiring harmful substances, while also allowing copper as electrode material
2Ease of manufacture
If sintering temperature is lowered to 1030°C or below for copper electrode compatibility, then copper can be used as internal electrode material offering excellent electrical conductivity, but sufficient dielectric characteristics and insulation resistance become difficult to achieve
Solution Approach 1:
The patent modifies the composition parameters by incorporating specific auxiliary components in controlled amounts that lower the sintering temperature to 1030°C or below. The BaTiO3 primary component combined with Re (0.01-5 mol%), Mn (0.1-5 mol%), and other auxiliaries creates a composition that sinters at low temperatures while maintaining dielectric characteristics sufficient for X7R or X5R applications
Solution Approach 2:
The patent employs a composite material system where BaTiO3 serves as the primary dielectric component and multiple auxiliary components (Re, Mn, V, Mo, Cu, B, Li, Sr, Ca) work synergistically. This composite structure enables low-temperature sintering compatibility with copper electrodes while preserving sufficient dielectric properties including insulation resistance and temperature characteristics
3Ease of manufacture
If copper is used as internal electrode material for low-temperature sintering, then excellent electrical conductivity is achieved, but longevity under high-temperature load becomes insufficient
Solution Approach 1:
The patent adjusts the composition parameters to include Cu (0.1-5 mol%) as an auxiliary component in the dielectric ceramic, which enhances the interface compatibility between copper electrodes and the dielectric layer. This composition modification, along with optimizing Re content (0.01-5 mol%) and Mn content (0.1-5 mol%), improves the stability of copper electrodes under high-temperature load while maintaining their excellent electrical conductivity
Solution Approach 2:
The patent uses a composite dielectric ceramic composition that includes Cu as an auxiliary component alongside BaTiO3 primary component and other auxiliaries (Re, Mn, V, Mo, B, Li, Sr, Ca). This composite structure creates a material system where the dielectric layer and copper electrode form a stable interface, enhancing longevity under high-temperature load while preserving the excellent electrical conductivity of copper
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 composition enables the production of laminated ceramic capacitors with excellent electrical conductivity and dielectric characteristics, meeting X7R or X5R standards, while avoiding harmful substances and achieving high-temperature reliability.
Implementation Method 1
which can be sintered at a low temperature of 1030° C. or below
Data Source
AI summary
A dielectric ceramic composition is represented by BaTiO3+aRe2O3+bMnO+cV2O5+dMoO3+eCuO+fB2O3+gLi2O+xSrO+yCaO (wherein Re represents one or more elements selected from among Eu, Gd, Dy, Ho, Er, Yb, and Y; and a-h each represents the mole number of each component with respect to 100 mol of the main component that is composed of BaTiO3). When the molar ratio of (Ba+Sr+Ca)/Ti contained in the dielectric ceramic composition is represented by m, the 0.10≦a≦0.50, 0.20≦b≦0.80, 0≦c≦0.12, 0≦d≦0.07, 0.04≦c+d≦0.12, 0≦e≦1.00, 0.50≦f≦2.00, 0.6≦(100(m−1)+2g)/2f≦1.3, and 0.5≦100(m−1)/2g≦5.1 are satisfied.