Borosilicate Glass Ceramic Component Pore Gradient

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Solution Overview

Problem

Existing ceramic electronic components with low dielectric constant materials face delamination issues due to significant shrinkage differences between Ag electrodes and ceramic materials during the firing process, caused by the use of inorganic foaming agents, which lead to tensile stress and poor stability of dielectric characteristics.

Innovation Solution

A ceramic electronic component with a borosilicate glass sintered body containing closed and open pores, where the pore diameters decrease away from the surface, and an Ag electrode is used, allowing for controlled shrinkage matching and preventing delamination by trapping gas generated during firing, thereby maintaining a stable dielectric constant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If inorganic foaming agent is used to reduce dielectric constant, then dielectric constant is reduced, but shrinkage difference between Ag electrode and ceramic material increases causing delamination

Engineering Contradiction:

Improvedielectric constantVSAvoidinterface bonding strength

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters of the glass material from conventional types to a specific borosilicate glass system with controlled ratios of SiO2, B2O3, Al2O3, and other oxides. This parameter change modifies the shrinkage characteristics of the ceramic body to match the Ag electrode shrinkage during firing, preventing delamination while maintaining low dielectric constant through the glass matrix structure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite ceramic material consisting of glass phases (borosilicate glass) combined with ceramic fillers (such as alumina, silica) and controlled pore structures. This composite structure achieves both low dielectric constant (through glass and pores) and matched shrinkage characteristics (through the ceramic filler framework), resolving the contradiction between dielectric performance and interface bonding reliability.

Inventive Principle:

Principle #40Composite materials

2Force

If distance between two coils is reduced to increase magnetic flux summation, then braking effect is improved, but stray capacitance increases causing resonance

Engineering Contradiction:

Improvebraking effectVSAvoidstray capacitance

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a controlled pore structure within the ceramic substrate, creating regions of reduced dielectric constant (air-filled pores) between the coils. This porous structure reduces the stray capacitance between adjacent coils, allowing them to be positioned closer together for enhanced magnetic flux summation and braking effect without suffering from resonant effects caused by excessive capacitance.

Inventive Principle:

Principle #31Porous materials

3Speed

If dielectric constant is reduced for high signal propagation velocity, then signal transmission efficiency is improved, but stability of dielectric characteristic deteriorates

Engineering Contradiction:

Improvesignal propagation velocityVSAvoiddielectric characteristic stability

Core Design Contradiction:

SpeedVSStability of the object's composition

Solution Approach 1:

The patent implements a non-uniform pore distribution within the ceramic substrate, with pore density and size varying in different regions. This local quality variation allows optimization of signal propagation velocity in specific areas (where lower dielectric constant is needed) while maintaining overall dielectric characteristic stability through the structured glass-ceramic matrix that provides mechanical and electrical stability throughout the component.

Inventive Principle:

Principle #3Local quality

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 component effectively prevents delamination and maintains a stable dielectric characteristic, ensuring reliable high-frequency signal transmission without resonance issues.

Implementation Method 1

The glass material has closed pores and open pores formed by trapping gas generated during the firing shrinkage process

Methodology Applied

Scientific EffectGas trapping:

Implementation Method 2

since an Ag electrode and a ceramic material have significantly-different shrinkage during a firing shrinkage process

Methodology Applied

Scientific EffectFiring shrinkage: Sintering

Implementation Method 3

gas caused by the decomposition of the foaming agent causes the ceramic material to expand during the shrinkage

Methodology Applied

Scientific EffectDecomposition: Decomposition (biological)

Data Source

PatentUS8780524B2Ceramic electronic component and method of manufacturing same

Publication Date: 2014.07.15 PANASONIC HOLDINGS CORP

AI summary

A ceramic electronic component includes a ceramic sintered body and an electrode provided on a surface of the ceramic sintered body. The electrode contains Ag. The ceramic sintered body contain glass material made of borosilicate glass. The glass material has closed pores and open pores therein. The closed pores and the open pores have diameters decreasing as being located away from the surface of the ceramic sintered body. This ceramic electronic component can prevent delamination of the electrode from the ceramic sintered body during a process of firing a green sheet.