Ceramic Component Side Margin Sintering Uniformity
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Solution Overview
Problem
In ceramic electronic devices with high lamination density, the sintering velocity is faster in the capacity section than in the side margin, leading to delayed densification of the side margin, which can degrade reliability in terms of lifetime characteristics and resistance to humidity at high temperatures.
Innovation Solution
A ceramic electronic component with a multilayer structure where the rare earth element in the side margin has a smaller ionic radius than in the capacity section, ensuring even distribution and promoting sintering of the side margin, thereby enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a common rare earth element is added to both the capacity section and side margin, then uneven distribution of elements during firing is suppressed and reliability is improved, but sintering velocity becomes faster in the capacity section than in the side margin, leading to delayed densification of the side margin
Solution Approach 1:
The patent applies local quality by using different rare earth elements with different ionic radii in different sections of the ceramic electronic component. Specifically, a first rare earth element with a larger ionic radius is used in the capacity section, while a second rare earth element with a smaller ionic radius is used in the side margin. This local differentiation allows each section to have optimal sintering characteristics tailored to its specific requirements, resolving the contradiction between overall reliability improvement and sintering uniformity.
Solution Approach 2:
The patent changes the ionic radius parameter of the rare earth element depending on the section. By selecting rare earth elements with different ionic radii (parameter change) for different sections, the sintering velocity and densification behavior can be controlled locally. This parameter change approach allows the capacity section to sinter faster while the side margin maintains appropriate sintering speed, solving the uniformity issue while preserving reliability benefits.
2Productivity
If the sintering velocity in the capacity section is faster than in the side margin, then the capacity section densifies quickly, but the side margin densification is delayed, degrading lifetime characteristic and resistance to humidity at high temperature
Solution Approach 1:
The patent implements local quality by tailoring the rare earth element composition to each section's specific needs. The capacity section uses a rare earth element that promotes faster sintering velocity for high productivity, while the side margin uses a different rare earth element that ensures adequate densification time for reliability. This localized optimization resolves the contradiction between production speed and product quality.
Solution Approach 2:
The patent changes the ionic radius parameter of the rare earth element to control sintering kinetics in different sections. By adjusting this fundamental material parameter, the sintering velocity can be optimized for the capacity section while ensuring the side margin achieves sufficient densification, thereby maintaining both productivity and lifetime characteristics.
3Productivity
If the sintering velocity in the capacity section is faster than in the side margin, then production efficiency is maintained, but resistance to humidity at high temperature is degraded due to insufficient side margin densification
Solution Approach 1:
The patent applies local quality by using different rare earth elements in different sections to address their distinct functional requirements. The capacity section prioritizes sintering velocity for productivity, while the side margin prioritizes densification quality for humidity resistance. This spatial differentiation of material composition resolves the contradiction between production efficiency and environmental resistance.
Solution Approach 2:
The patent changes the ionic radius parameter of the rare earth element to independently control sintering behavior in each section. This parameter adjustment enables the capacity section to achieve fast sintering for high productivity while the side margin achieves adequate densification for humidity resistance, eliminating the trade-off between these two properties.
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 approach effectively reduces the difference in sintering progress between the capacity and side margins, improving the reliability of the ceramic electronic component by ensuring proper densification and resistance to humidity.
Implementation Method 1
sintering velocity is larger in the capacity section than in the side margin... When the sintering of the side margin is delayed, densifying of the side margin is not promoted
Data Source
AI summary
A ceramic electronic component includes a multilayer structure including dielectric layers and internal electrode layers, the internal electrode layers being alternately exposed to two edge faces of the multilayer chip opposite to each other. A rare earth element of a side margin has an ionic radius smaller than that of a rare earth element of a capacity section. The rare earth element of the side margin is a rare earth element when only the rare earth element is added to the side margin, or a rare earth element with a largest amount when rare earth elements are added to the side margin. The rare earth element of the capacity section is a rare earth element when only the rare earth element is added to the capacity section, or a rare earth element with a largest amount when rare earth elements are added to the capacity section.