Ceramic Component External Electrodes Prevent Fusing
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Solution Overview
Problem
Existing methods for producing ceramic electronic components, such as multi-layer ceramic capacitors, face challenges in preventing fusing between external electrodes during the baking process, leading to increased costs and man-hours due to the need for metal additives or specialized trays.
Innovation Solution
A ceramic electronic component with external electrodes formed from crystal particles containing barium (Ba), zinc (Zn), silicon (Si), and oxygen (O), deposited on the surface of the ceramic body, which inhibits glass deposition and fusing by baking the electrode material under a humidified atmosphere, using an electrode material that may include flaky metal powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the baking temperature is decreased to suppress fusing of external electrodes, then fusing is inhibited, but the degree of compactness of external electrodes is reduced
Solution Approach 1:
The patent changes the chemical composition parameters of the external electrode by incorporating specific glass components (barium borosilicate glass with 40-70 wt% SiO2, 10-30 wt% B2O3, and 5-20 wt% BaO) and metal powder (90-99 wt% Cu, 1-10 wt% Ni). This compositional parameter change allows the external electrode to maintain structural integrity and compactness at lower baking temperatures, preventing fusing while preserving reliability.
Solution Approach 2:
The patent creates a composite external electrode structure combining multiple materials: copper powder (90-99 wt%), nickel powder (1-10 wt%), and barium borosilicate glass (10-30 wt%). This composite material approach enables the external electrode to achieve both low-temperature processability and high compactness, resolving the contradiction between preventing fusing and maintaining reliability.
2Object-generated harmful factors
If metal additive is added to electrically conductive paste to inhibit fusing, then fusing is prevented, but production costs and man-hours increase
Solution Approach 1:
The patent merges the functions of multiple additives into a single integrated glass component (barium borosilicate glass) that simultaneously provides fusing prevention, bonding, and compactness enhancement. This consolidation eliminates the need for separate metal additives and simplifies the manufacturing process, reducing both costs and man-hours while effectively preventing fusing.
Solution Approach 2:
The barium borosilicate glass component in the external electrode self-regulates the baking process by melting at appropriate temperatures to form a protective layer that prevents fusing between adjacent electrodes. This self-service mechanism eliminates the need for additional process steps or specialized equipment, thereby reducing production complexity and costs.
3Ease of manufacture
If glass component is melted during baking to form external electrodes, then external electrodes are formed, but fusing between adjacently disposed external electrodes occurs
Solution Approach 1:
The patent applies local quality control by designing the glass component to melt and form a protective layer specifically at the interfaces between external electrodes and the ceramic body, while maintaining the structural integrity of adjacent external electrodes. The barium borosilicate glass composition (40-70 wt% SiO2, 10-30 wt% B2O3, 5-20 wt% BaO) is optimized to provide localized bonding without causing fusing between adjacent electrodes.
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
Effectively prevents fusing between components during the baking process, improving the reliability and compactness of external electrodes while reducing production costs and time, as evidenced by the distribution of rod-like crystal particles on the surface of the electrodes.
Implementation Method 1
depositing crystal particles containing Ba, Zn, Si, and oxygen (O) by baking the electrode material under a humidified atmosphere
Implementation Method 2
the glass component contained in the electrically conductive paste is melted
Data Source
AI summary
A ceramic electronic component includes: a ceramic body that includes internal electrodes; and an external electrode that includes a plurality of crystal particles containing Ba, Zn, Si, and O, the external electrode being formed on a surface of the ceramic body and connected to the internal electrodes.