Multilayer Ceramic Component Electrode Shrinkage Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multilayer ceramic electronic components face challenges in ensuring reliable electrical connection between thin inner electrode layers and outer electrodes due to differential shrinkage ratios during firing, leading to potential separation and electric discharge issues.
Innovation Solution
The design involves forming ceramic layers with a thin portion that continuously reduces in thickness near the end portion and inner electrode layers with a thick portion that increases in thickness to match the ceramic layer shape, ensuring a larger connection area and maintaining electrical connection even after firing, with the outer electrode being integral with the inner electrode layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of inner electrode layers and ceramic layers is reduced to decrease component size, then the size and height profile of the multilayer ceramic electronic component is reduced, but the inner electrodes become separated more easily from the end surfaces of the ceramic sinter due to differential shrinkage, making it difficult to ensure electrical connection with outer electrodes
Solution Approach 1:
The patent applies local quality by creating a thick portion of the inner electrode layer at the end surface region where electrical connection is critical. This local thickening ensures reliable exposure and connection with outer electrodes, while the central portion remains thin to achieve miniaturization goals. The non-uniform thickness distribution resolves the contradiction between size reduction and connection reliability.
Solution Approach 2:
The patent implements preliminary action by pre-forming the inner electrode layer with a thick portion at the end surface before the firing process. This preliminary structural preparation ensures that even after differential shrinkage during firing, the inner electrodes remain exposed at the end surfaces and maintain reliable electrical connection with outer electrodes, preventing separation issues.
2Manufacturing precision
If the inner electrodes significantly shrink in directions separated from the end surfaces of the ceramic sinter during firing, then the inner electrodes may not be exposed through the end surfaces, but polishing the end surface by barrel polishing cannot ensure electrical connection between inner electrodes and outer electrodes
Solution Approach 1:
The patent creates a local thick portion of the inner electrode layer at the end surface region, ensuring that even after significant shrinkage during firing, the inner electrodes remain exposed at the end surfaces. This local thickening provides a margin that compensates for shrinkage, making polishing processes effective and ensuring reliable electrical connection with outer electrodes.
Solution Approach 2:
The patent implements beforehand cushioning by pre-designing the inner electrode layer with a thick portion at the end surface before firing. This structural cushioning compensates for the expected shrinkage during the firing process, ensuring that the inner electrodes remain exposed at the end surfaces and maintain reliable electrical connection, preventing the harmful effect of complete retraction.
3Volume of moving object
If the inner electrodes are thin films to reduce component size, then the component size is reduced, but the inner electrodes become separated more easily from the end surfaces due to differential shrinkage ratios between inner electrodes and ceramic layers
Solution Approach 1:
The patent applies local quality by creating a thick portion of the inner electrode layer at the end surface region while keeping the central portion thin. This local thickening provides positional stability at the critical end surface area where connection occurs, preventing separation due to differential shrinkage, while maintaining overall component miniaturization through the thin central region.
Solution Approach 2:
The patent implements preliminary action by pre-forming the inner electrode layer with a thick portion at the end surface before the firing process. This preliminary structural preparation ensures positional stability during the firing process, preventing the inner electrodes from retracting too far from the end surfaces despite differential shrinkage between the inner electrodes and ceramic layers.
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 configuration ensures reliable electrical connection between inner and outer electrodes, reducing the risk of electric discharge and maintaining connectivity despite shrinkage, resulting in a highly reliable multilayer ceramic electronic component.
Implementation Method 1
the inner electrodes are exposed to the end surfaces of the ceramic sinter by oxidizing and expanding the inner electrodes in firing the multilayer body
Implementation Method 2
the inner electrodes are exposed to the end surfaces of the ceramic sinter by oxidizing and expanding the inner electrodes in firing the multilayer body
Implementation Method 3
After the produced multilayer body is pressed in the thickness direction, it is fired, and a ceramic sinter is thus obtained
Data Source
AI summary
A multilayer ceramic electronic component includes a multilayer body including ceramic layers and inner electrode layers, the inner electrode layers being disposed on interfaces between the ceramic layers, and an outer electrode on an external surface of the multilayer body and electrically connected to first end portions of the inner electrode layers exposed to the external surface of the multilayer body. Each of the ceramic layers includes a thin portion with a continuously reducing thickness near the first end portion. Each inner electrode layer includes a thick portion near a connection with the outer electrode, the thick portion having a thickness continuously increasing toward the connection on a first side in accordance with a shape of the thin portion in the ceramic layer. A distance between a second end portion in the inner electrode layer not joined to the outer electrode, and the thick portion adjacent to the second end portion is equal to or longer than an interlayer distance between the inner electrode layers.