Ceramic Capacitor Moisture Resistance via Inorganic Insulating Layers
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges in achieving miniaturization and high capacity while maintaining moisture resistance reliability, as reducing the thickness of dielectric and internal electrode layers degrades moisture resistance.
Innovation Solution
A ceramic electronic component design featuring a dielectric layer and internal electrodes with a body structure, where inorganic insulating layers of SiO2, Al2O3, or ZrO2 are applied to the external electrodes and surfaces, with thicknesses ranging from 20 nm to 150 nm to enhance moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of dielectric layer and internal electrode is reduced to achieve miniaturization and high capacity, then the number of layers increases and capacity improves, but moisture resistance reliability degrades
Solution Approach 1:
The patent applies a composite protective structure consisting of multiple inorganic insulating layers (first, second, and third inorganic insulating layers) with different materials and positions. These layers form a composite barrier system that provides enhanced moisture resistance without requiring increased thickness of individual layers, thus maintaining miniaturization while improving reliability
Solution Approach 2:
The patent extends protection from a two-dimensional surface coating to a three-dimensional multi-layer structure that wraps around the external electrodes and covers multiple surfaces (third, fourth, fifth, and sixth surfaces) of the body. This spatial expansion creates a comprehensive moisture barrier that protects the thinned structure from all directions
2Quantity of substance
If the thickness of margin portion, cover portion, and external electrode is reduced to secure maximum valid capacity, then capacity increases, but moisture resistance reliability degrades
Solution Approach 1:
The patent applies different protective strategies to different regions: the first and second inorganic insulating layers are applied locally to the external electrodes where moisture penetration is most critical, while the third inorganic insulating layer covers the body surfaces. This localized protection allows thinning of margin and cover portions while maintaining overall moisture resistance
Solution Approach 2:
The inorganic insulating layers are applied in advance to the external electrodes and body surfaces before final assembly, creating a pre-established moisture barrier. This preliminary protection prevents moisture from attacking the thinned margin and cover portions from the outset
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
This design improves moisture resistance reliability even when the dielectric layer thickness is 0.4 μm or less, and the cover portion thickness is 20 μm or less, preventing moisture penetration and maintaining capacitance and miniaturization.
Implementation Method 1
The first, second and third inorganic insulating layers comprise at least one selected from the group of SiO2, Al2O3 and ZrO2
Data Source
AI summary
A ceramic electronic component includes a body including a dielectric layer and first and second internal electrodes, a first external electrode including a first electrode layer electrically connected to the first internal electrode, a first inorganic insulating layer disposed on the first electrode layer, and a first plating layer disposed on the first inorganic insulating layer, a second external electrode including a second electrode layer electrically connected to the second internal electrode, a second inorganic insulating layer disposed on the second electrode layer, and a second plating layer disposed on the second inorganic insulating layer, and a third inorganic insulating layer disposed on the body and connected to the first and second inorganic insulating layers. The first, second and third inorganic insulating layers comprise one or more of SiO2, Al2O3 and ZrO2, and the first, second and third inorganic insulating layers have a thickness within a range from 20 nm to 150 nm.