Multilayer Ceramic Component Residual Carbon Removal Paths
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Solution Overview
Problem
The challenge in miniaturizing multilayer ceramic electronic components is the difficulty in removing residual carbon, which affects the reliability due to varying firing behaviors and can lead to internal electrode disconnection, especially in high-capacity and large-sized chips.
Innovation Solution
Incorporating residual carbon removing path parts on both sides of internal electrodes, exposed to the ceramic body's surfaces, which are formed from the same material as the internal electrodes and are designed to protrude and be symmetrical or offset, along with a margin part using nonconductive powder to cover and insulate these paths, facilitating efficient carbon removal during the debinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of binder is increased to provide strength to thinned multilayer ceramic electronic component, then the strength is improved, but the residual carbon removal becomes difficult
Solution Approach 1:
The internal electrode structure is segmented by adding protruding parts that extend toward the surface of the ceramic body. These protruding parts create separate pathways for residual carbon removal, allowing carbon to escape through multiple routes rather than being trapped within the bulk material. This segmentation approach enables effective carbon removal even when binder content is increased for strength.
Solution Approach 2:
The protruding parts of the internal electrode act as intermediary structures that facilitate the removal of residual carbon. These protrusions create channels or pathways that serve as mediators between the internal carbon-containing regions and the external environment, enabling carbon to be removed during the firing process without compromising the overall structural integrity provided by the binder.
2Quantity of substance
If the residual amount of residual carbon is large in the multilayer ceramic electronic component, then the capacity is increased, but the firing behavior uniformity deteriorates
Solution Approach 1:
By dividing the internal electrode structure into multiple regions with protruding parts, the patent creates multiple independent carbon removal pathways. This segmentation ensures that residual carbon can be efficiently removed from different regions of the component during firing, maintaining uniform firing behavior even when the overall carbon content is high for increased capacity.
Solution Approach 2:
The protruding parts are strategically positioned at specific locations within the internal electrode structure to create localized carbon removal channels. This local quality approach ensures that regions with high carbon concentration have dedicated pathways for carbon removal, maintaining firing uniformity while allowing high overall carbon content for increased capacity.
3Quantity of substance
If the residual amount of residual carbon is large in the multilayer ceramic electronic component, then the capacity is increased, but the internal electrode disconnection risk increases
Solution Approach 1:
The internal electrode is divided into multiple segments with protruding parts that extend toward the surface. This segmentation creates multiple independent pathways for carbon removal, preventing carbon accumulation that could cause disconnection. The protruding parts ensure that even if carbon is present in high amounts for increased capacity, it can be removed through multiple routes, preventing internal electrode disconnection.
Solution Approach 2:
The protruding parts are pre-formed in the internal electrode structure before the firing process. These preliminary structural features create predetermined pathways for carbon removal during firing. By preparing these escape routes in advance, the patent prevents carbon accumulation that could lead to internal electrode disconnection, even when high carbon content is present for increased capacity.
Data Source
AI summary
There is provided a multilayer ceramic electronic component, including: a ceramic body including a dielectric layer and having first and third surfaces opposing each other in a length direction of the dielectric layer and second and fourth surfaces opposing each other in a width direction thereof; and a multilayer part including a first internal electrode and a second internal electrode disposed to oppose each other, while having the dielectric layer interposed there between in the ceramic body, and exposed to the first and third surfaces of the ceramic body, respectively; wherein one or more residual carbon removing path parts are formed to be protruded on both side of the first and second internal electrodes in a length direction of the ceramic body.