Laminated Ceramic Capacitor TiO2 Outer Layers Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laminated ceramic capacitors face high production costs due to the use of expensive dielectric materials for both inner and outer ceramic layers, and are prone to structural defects from alkaline-earth metal dissolution in organic acids during soldering, leading to residual stress and elution issues.
Innovation Solution
The use of TiO2 as the main constituent for outer ceramic layers, which are less expensive and resistant to organic acid dissolution, allowing for a distinction in color between principal and side surfaces to facilitate proper mounting and reduce elution and structural defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the same expensive dielectric material is used for both inner and outer ceramic layers, then electrical characteristics are maintained, but production cost increases
Solution Approach 1:
The patent applies different dielectric materials to different regions of the capacitor structure. The inner ceramic layers use expensive perovskite-type compounds for optimal electrical performance, while the outer ceramic layers use cheaper materials since they do not directly contribute to electrical characteristics. This local differentiation resolves the contradiction by optimizing material usage based on functional requirements.
Solution Approach 2:
The capacitor body is segmented into functionally distinct regions: inner ceramic layers that provide electrical functionality and outer ceramic layers that provide structural protection. By separating these functions and using appropriate materials for each segment, the patent reduces overall cost while maintaining electrical performance.
2Reliability
If perovskite-type compounds with alkaline-earth metals are used in outer ceramic layers, then electrical properties are improved, but resistance to organic acid dissolution decreases
Solution Approach 1:
The patent assigns different material compositions to different regions based on their specific requirements. The inner layers use perovskite-type compounds optimized for electrical properties, while the outer layers use materials with high resistance to organic acid dissolution. This local optimization resolves the contradiction by matching material properties to functional demands.
Solution Approach 2:
The outer ceramic layers use simpler, more chemically stable materials that are less expensive and provide protective functionality. These outer layers act as a sacrificial barrier that protects the valuable inner layers from chemical attack during soldering processes.
3Stability of the object's composition
If outer ceramic layers are made with materials resistant to organic acid dissolution, then structural stability is improved, but production cost may increase
Solution Approach 1:
The patent implements local quality optimization by using chemically stable materials only where needed (outer protective layers) rather than throughout the entire structure. This targeted approach provides structural stability where required while controlling overall production costs.
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 approach reduces production costs and minimizes elution of outer ceramic layers into organic acids, enhancing the reliability and stability of laminated ceramic capacitors by using TiO2 for outer layers, which are not essential for electrical characteristics and are resistant to acid dissolution.
Implementation Method 1
TiO2 is hardly dissolved in organic acids
Data Source
AI summary
A laminated ceramic capacitor having a laminated body composed of a plurality of ceramic layers for inner layers; a plurality of internal electrodes at the interfaces between the plurality of ceramic layers for inner layers; and a plurality of ceramic layers for outer layers, provided on the top and bottom so as to sandwich the plurality of ceramic layers for inner layers. The ceramic layers for inner layers are composed of a material containing a multiple oxide including an alkaline-earth metal. The ceramic layers for outer layers respectively have TiO2 ceramic layers containing TiO2 as their main constituent for certain layers including the outermost layers, and multiple oxide ceramic layers containing a multiple oxide including an alkaline-earth metal for the other layers.