Multi-layered Ceramic Component External Electrode Blister Prevention
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Solution Overview
Problem
The challenge in multi-layered ceramic electronic components is to maintain reliable contact between the ceramic body and external electrodes while preventing blister defects, which occur due to gas emission at high temperatures and the degradation of the nickel internal electrode surface, especially when using fine copper powder and high firing temperatures.
Innovation Solution
Incorporating a second phase material occupying 1 to 80% of the area of glass in the external electrodes, selected from barium, silicon, or calcium, to control glass fluidity at high temperatures, ensuring the copper-nickel alloy is strongly formed before the glass moves, thereby improving contact properties and preventing blister defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine copper powder is used to improve contact property and compactness, then contact property between chip and external electrode is improved, but blister defect is generated due to short firing time preventing gas emission
Solution Approach 1:
The patent modifies the chemical composition parameters of the glass material by incorporating specific metal oxides (B2O3: 20-40 wt%, SiO2: 30-50 wt%, Al2O3: 10-20 wt%) to alter the glass transition temperature and viscosity characteristics. This parameter change enables the glass to maintain appropriate fluidity at high firing temperatures, allowing sufficient time for gas emission while ensuring proper contact property and compactness.
2Manufacturing precision
If firing temperature is increased to improve contact property, then contact property between ceramic body and external electrode is improved, but glass moves to boundary surface before copper-nickel alloy layer is formed, deteriorating contact property
Solution Approach 1:
The patent adjusts the glass composition parameters to achieve an optimal glass transition temperature range and viscosity profile. The specific formulation (B2O3: 20-40 wt%, SiO2: 30-50 wt%, Al2O3: 10-20 wt%, plus optional metal oxides) ensures that at high firing temperatures, the glass maintains sufficient structural stability to remain at the boundary surface without excessive movement, while still providing adequate fluidity for proper contact formation.
Solution Approach 2:
The patent creates a composite glass system combining multiple oxide components (B2O3, SiO2, Al2O3, and optional metal oxides like PbO, ZnO, BaO) to achieve synergistic effects. This composite material provides both the necessary fluidity for contact formation and the structural stability to prevent excessive glass movement at high temperatures, resolving the contradiction between contact property improvement and glass position stability.
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
This approach enhances the reliability of multi-layered ceramic electronic components by reducing glass fluidity, promoting gas emission during firing and maintaining contact integrity, even at high temperatures, thus preventing blister defects and ensuring excellent capacitance and insulation resistance.
Implementation Method 1
the first and second external electrodes include a conductive metal and glass and further include a second phase material occupying an area of 1 to 80% with respect to an area of glass in the first and second external electrodes
Implementation Method 2
it may be difficult to form a copper-nickel alloy layer that should be formed at the time of forming the external electrode
Implementation Method 3
a blister defect generated since gas generated at relatively high temperatures after firing is not emitted may be generated
Data Source
AI summary
There is provided a multi-layered ceramic electronic component including a ceramic body including a dielectric layer, first and second internal electrodes disposed within the ceramic body so as to face each other, having the dielectric layer interposed therebetween, and a first external electrode electrically connected to the first internal electrodes and a second external electrode electrically connected to the second internal electrodes, wherein the first and second external electrodes include a conductive metal and glass and further include a second phase material occupying an area of 1 to 80% with respect to an area of glass in the first and second external electrodes.