Multilayer Ceramic Capacitor Insulation Restoration via Electrode Melting
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Solution Overview
Problem
Multilayer ceramic capacitors with nickel internal electrode layers face issues with insulation failure and overheating due to short-circuits caused by high voltage or mechanical stress, leading to a loss of insulation properties and potential overheating.
Innovation Solution
The use of ceramic elements with dielectric layers containing barium titanate and sub-components like boron oxide or lithium oxide, combined with internal electrode layers made of copper or silver, and a controlled coverage ratio of 98% or less, allows for insulation restoration by passing an electric current through the component, preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the coverage ratio of internal electrode layers to dielectric layers is increased to improve capacitance, then capacitance increases, but the risk of short-circuit and insulation failure increases
Solution Approach 1:
The patent changes the material parameters of both the dielectric layer (adding boron oxide and lithium oxide to barium titanate) and the internal electrode layer (using copper and/or silver instead of nickel) to achieve a balance between capacitance and insulation reliability, allowing the coverage ratio to be optimized without compromising insulation properties
2Ease of manufacture
If nickel is used as the main component of internal electrode layers, then manufacturing is simplified, but insulation restoration capability after short-circuit is poor
Solution Approach 1:
The patent changes the material composition of the internal electrode layer from nickel to copper and/or silver, which have better electrical conductivity and melting characteristics that enable insulation restoration after short-circuit by allowing current to pass through and melt the short-circuited electrode portions
Solution Approach 2:
The patent uses composite materials in the dielectric layer (barium titanate with boron oxide and lithium oxide) that provide both high capacitance and enhanced insulation restoration capability, creating a material system that addresses both manufacturing ease and reliability
3Quantity of substance
If the coverage ratio of internal electrode layers is set high to maximize capacitance, then initial capacitance increases, but the ability to restore insulation after short-circuit decreases
Solution Approach 1:
The patent optimizes the coverage ratio parameter to 98% or less, creating a small gap between internal electrode layers that serves as a safety margin for insulation restoration, while compensating for the capacitance reduction through enhanced dielectric material composition
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 configuration enables the multilayer ceramic electronic component to maintain insulation properties even after a short-circuit, preventing overheating and ensuring the component functions effectively by melting and scattering the internal electrodes during current flow.
Implementation Method 1
an electric current flows once again through a portion where the internal electrode layers are short-circuited, and the internal electrodes are thereby melted and scattered
Data Source
AI summary
A multilayer ceramic electronic component includes a ceramic element body formed by alternately laminating dielectric layers and internal electrode layers. The dielectric layers include a main component containing barium titanate and a sub-component containing boron oxide and/or lithium oxide. The internal electrode layers include a main component of copper and/or silver. A coverage ratio of the internal electrode layers to the dielectric layers is 98% or less.