Core-Shell Dielectric Composition for Reliable Multilayer Capacitors
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges in achieving smaller size, higher reliability, and improved electrical properties, especially when exposed to high heat and vibrations in automotive applications.
Innovation Solution
A multilayer electronic component with a dielectric layer composed of calcium (Ca), strontium (Sr), zirconium (Zr), titanium (Ti), manganese (Mn), yttrium (Y), and silicon (Si) with a core-shell structure in the dielectric grains, where Ys/Yc > 9, enhances dielectric properties and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the dielectric layer uses a simple composition, then the manufacturing process is simpler, but the dielectric properties and reliability are insufficient
Solution Approach 1:
The dielectric layer employs a composite material system consisting of Ca-Zr-Ti-O base material combined with Mn-Y-Si dopants. This composite approach enables simultaneous improvement of dielectric constant, quality factor, and breakdown voltage through synergistic effects of multiple elements, resolving the contradiction between enhanced reliability and composition complexity.
Solution Approach 2:
The invention introduces a core-shell structure in dielectric grains where the core contains Ca-Zr-Ti-O with specific dopant concentrations and the shell has different compositional characteristics. This local differentiation of material properties within the grain structure optimizes both dielectric performance and manufacturing feasibility by concentrating complex composition only where necessary.
2Volume of moving object
If the chip size is reduced, then the product size is smaller, but the electrical properties and reliability deteriorate
Solution Approach 1:
The invention optimizes critical parameters including the Ys/Yc ratio (shell-to-core yttrium content ratio greater than 9), dopant concentrations (Mn: 0.01-5 mol%, Y: 0.01-5 mol%, Si: 0.01-5 mol%), and grain size distribution. These parameter optimizations enable miniaturization while maintaining electrical properties by enhancing dielectric constant and breakdown voltage at smaller scales.
Solution Approach 2:
The composite Ca-Zr-Ti-O system with Mn-Y-Si dopants provides superior electrical properties that enable chip miniaturization. The composite structure maintains high dielectric constant and breakdown voltage even at reduced chip dimensions, resolving the contradiction between small size and reliable electrical performance.
3Adaptability or versatility
If the electronic component is exposed to high heat and vibrations, then the operational capability is maintained, but the reliability decreases
Solution Approach 1:
The Mn-Y-Si dopants serve as a protective mechanism against high heat and vibrations. The dopants create a more stable crystal structure and reduce defect formation during thermal and mechanical stress, effectively cushioning the base material against degradation from environmental stressors before damage occurs.
Solution Approach 2:
The invention optimizes compositional parameters (dopant types and concentrations) and microstructural parameters (grain size, core-shell structure) to enhance thermal and mechanical stability. These parameter optimizations enable the component to maintain reliability under high heat and vibration conditions by improving structural resilience.
Data Source
AI summary
A body including a dielectric layer and internal electrodes disposed alternately with the dielectric layer interposed therebetween; and external electrodes disposed on the body, wherein the dielectric layer includes a main component containing calcium (Ca), strontium (Sr), zirconium (Zr) and titanium (Ti) and a sub-component containing manganese (Mn), yttrium (Y) and silicon (Si), wherein the dielectric layer includes a plurality of dielectric grains and grain boundaries disposed between adjacent dielectric grains, and at least a portion of the plurality of dielectric grains has a core-shell structure, a content of yttrium (Y) included in a core relative to 100 moles of zirconium (Zr) included in the core and a shell is defined as Yc, a content of yttrium (Y) included in the shell relative to 100 moles of zirconium (Zr) included in the core and the shell is defined as Ys, and Ys/Yc>9 is satisfied.