Multilayer Ceramic Component Electrode Alignment Control
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Solution Overview
Problem
Multilayer ceramic electronic components, particularly capacitors, face defects in internal electrode alignment due to the dome shape of printed electrodes, which worsens as components miniaturize and capacitance increases, leading to reliability issues during lamination and mounting processes.
Innovation Solution
The solution involves controlling the ratio of T2 (distance between the highest and lowest points) to T1 (greatest distance between upper and lower internal electrodes) to less than 0.05, achieved by managing the discharge amount of conductive paste during internal electrode pattern formation, using metals like palladium, palladium-silver alloy, nickel, or copper, and ensuring a printed width of 300 μm or less, to prevent electrode deviation and alignment defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the printed width of the internal electrode is reduced to achieve miniaturization and increased capacitance, then the component size decreases and capacitance increases, but the internal electrode transforms into a dome shape causing alignment defects during lamination
Solution Approach 1:
The patent applies parameter changes by controlling the ratio T2/T1 to be 0.05 or less, where T1 is the greatest distance between upper and lower outermost internal electrodes and T2 is the distance between the highest and lowest points of the internal electrode in the thickness direction. This parameter control prevents the internal electrode from forming a dome shape that would cause alignment defects, while still allowing miniaturization and increased capacitance through reduced printed width (300 μm or less) and increased number of laminated layers (50 layers or more).
Solution Approach 2:
The patent applies preliminary action by pre-controlling the shape of the internal electrode during the printing process to maintain a flat profile before lamination. By managing the discharge amount of conductive paste and controlling the T2/T1 ratio in advance, the internal electrode is prepared in a shape that will not transform or deform during the subsequent lamination and pressing processes, thereby preventing alignment defects before they occur.
2Quantity of substance
If the number of laminated layers is increased to achieve larger capacitance in miniaturized components, then capacitance increases, but alignment defects of internal electrodes worsen
Solution Approach 1:
The patent applies parameter changes by establishing the T2/T1 ratio control (0.05 or less) as a fundamental parameter that remains consistent regardless of the number of laminated layers. This allows the manufacturing process to produce components with 50 layers or more while maintaining internal electrode alignment precision, thereby achieving increased capacitance through quantity of layers without suffering from worsening alignment defects.
3Length of moving object
If the printed width of the internal electrode is reduced to achieve miniaturization, then component size decreases, but the dome shape transformation during lamination causes alignment defects
Solution Approach 1:
The patent applies parameter changes by controlling the T2/T1 ratio to be 0.05 or less, which fundamentally changes the shape characteristics of the internal electrode from a dome shape to a flat shape. This parameter control allows the printed width to be reduced to 300 μm or less for miniaturization while maintaining shape stability during lamination, preventing the dome shape transformation that would otherwise cause alignment defects.
Solution Approach 2:
The patent applies preliminary action by pre-controlling the conductive paste discharge amount during the printing process to ensure the internal electrode forms a flat profile before lamination. This preliminary shape control prevents subsequent dome shape transformation during the lamination and pressing processes, maintaining shape stability even when the printed width is reduced for miniaturization.
Data Source
AI summary
There are provided a multilayer ceramic electronic component and a method of manufacturing the same, the multilayer ceramic electronic including: a ceramic body; and a plurality of internal electrodes laminated within the ceramic body, wherein, when T1 is the greatest distance between an upper outermost internal electrode and a lower outermost internal electrode among the plurality of internal electrodes and T2 is the distance between the highest point and the lowest point in each of the upper outermost internal electrode and the lower outermost internal electrode in a thickness direction of the ceramic body, T2/T1<0.05 is satisfied, and thus, defects in alignment of internal electrodes of the multilayer ceramic electronic component may be suppressed.