Multilayer Capacitor Liquid Pockets Suppress Grain Growth
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Solution Overview
Problem
Multilayer capacitors face challenges in achieving high reliability due to defects in ceramic bodies and internal electrodes, particularly with device miniaturization, where structural stability and additive dispersibility are critical for improved performance.
Innovation Solution
A multilayer capacitor design that incorporates a ceramic sintered body with liquid pockets at grain boundaries, which suppresses grain growth and includes BT-based ceramic materials with Si or Al additives, enhancing sintering properties and reliability by controlling grain size and void distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of internal electrodes or dielectric layers is decreased to achieve miniaturization, then the device size is reduced, but structural stability and reliability deteriorate due to increased defects
Solution Approach 1:
The patent introduces liquid pockets at specific locations (grain boundaries) within the ceramic sintered body to create local structural modifications. These liquid pockets are strategically positioned to suppress grain growth at critical interfaces without affecting the overall device dimensions, thereby maintaining miniaturization while locally enhancing structural stability and reliability.
Solution Approach 2:
The patent creates a composite structure by incorporating liquid pockets into the ceramic sintered body matrix. This composite approach combines the ceramic material with liquid phase regions, resulting in a material that exhibits both the miniaturization capability of thin layers and the enhanced reliability provided by controlled grain growth suppression at grain boundaries.
2Reliability
If additives are introduced to improve sintering properties and grain size control, then reliability is enhanced, but the complexity of material composition increases
Solution Approach 1:
The patent utilizes additives (such as SiO2, Al2O3, or other glass-forming oxides) to change the physical and chemical parameters of the ceramic sintered body during sintering. These additives modify the liquid phase formation temperature, viscosity, and composition, thereby controlling grain growth and enhancing sintering properties. The complexity is managed by selecting additives that form eutectic compositions with the base ceramic material, allowing effective sintering control with minimal compositional variation.
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 design improves the reliability of multilayer capacitors by maintaining excellent insulation properties and withstanding harsh conditions, with enhanced capacitance and miniaturization capabilities, as evidenced by improved grain size control and increased resistance to physical and chemical stress.
Implementation Method 1
The liquid pocket may be disposed at a grain boundary in the ceramic sintered body
Implementation Method 2
a ceramic sintered body including a liquid pocket
Data Source
AI summary
A multilayer capacitor includes a body in which a plurality of internal electrodes are stacked, including a ceramic sintered body; and external electrodes disposed on an external surface of the body and electrically connected to the internal electrodes. The ceramic sintered body includes a liquid pocket.