Ceramic Electronic Component Boundary Reaction Layer Adhesion
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Solution Overview
Problem
Existing laminated ceramic electronic components face issues with insufficient adhesion between dielectric layers, leading to peeling, which limits the combination of materials used in these components.
Innovation Solution
A ceramic electronic component is designed with a first dielectric layer containing BaO, Nd2O3, and TiO2, a second dielectric layer with a different material, and a boundary reaction layer containing at least one of Zn, Ti, Cu, and Mg, which are formed through a process involving calcination in an oxygen atmosphere to enhance adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different dielectric layer materials are simultaneously calcined to laminate, then material versatility is improved, but adhesion between layers deteriorates causing peeling
Solution Approach 1:
A boundary reaction layer containing ZnO, TiO2, CuO, and MgO is formed at the interface between different dielectric layers through controlled calcination. This intermediate layer acts as a chemical bridge that enhances adhesion between dissimilar dielectric materials, allowing versatile material combinations while preventing peeling. The boundary reaction layer specifically addresses the adhesion problem by creating a transition zone with compatible chemical properties between the first and second dielectric layers.
Solution Approach 2:
The patent employs composite material structures where the boundary reaction layer is composed of multiple metal oxides (ZnO, TiO2, CuO, MgO) that work synergistically to enhance interfacial adhesion. This composite approach at the interface allows different dielectric layer materials to be combined while maintaining structural integrity, thus enabling material versatility without compromising reliability.
2Reliability
If dielectric layers with different materials are laminated, then functional performance is improved, but manufacturing complexity increases due to adhesion control
Solution Approach 1:
The base materials for the boundary reaction layer (ZnO, TiO2, CuO, MgO) are pre-mixed into the green sheet formulation before lamination. This preliminary preparation ensures that during calcination, the boundary reaction layer forms automatically at the interfaces without requiring additional processing steps. The complex adhesion control is thus simplified by embedding the solution within the material composition itself rather than adding separate process steps.
3Productivity
If multiple dielectric layers are simultaneously calcined, then production efficiency is improved, but adhesion control becomes difficult
Solution Approach 1:
The patent specifies precise calcination parameters (temperature range, atmosphere composition, heating rate) to control the formation of the boundary reaction layer during simultaneous calcination of multiple dielectric layers. By optimizing these parameters, the boundary reaction layer forms with appropriate thickness and composition, ensuring adhesion quality while maintaining the efficiency benefits of simultaneous calcination. The parameter control transforms a potentially problematic process into a reliable manufacturing method.
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 solution effectively prevents peeling between dielectric layers, allowing for the stable lamination of components with different materials and maintaining strong adhesive strength, thereby improving the reliability and performance of ceramic electronic components.
Implementation Method 1
a boundary reaction layer formed between the first dielectric layer and the second dielectric layer and containing at least one of Zn, Ti, Cu, and Mg
Implementation Method 2
calcining the first mixture in oxygen atmosphere at a temperature of 800° C. or more and 950° C. or less to produce a first finished material
Data Source
AI summary
A ceramic electronic component includes a first dielectric layer, a second dielectric layer, and a boundary reaction layer. The first dielectric layer is a layer containing BaO, Nd2O3, and TiO2, the second dielectric layer is a layer containing a material different from the material of the first dielectric layer, and the boundary reaction layer is a layer formed between the first dielectric layer and the second dielectric layer and containing at least one of Zn, Ti, Cu, and Mg.