Dielectric Ceramic Composition with M4R6O(SiO4)6 Diffusive Phase
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Solution Overview
Problem
Existing dielectric ceramic compositions used in multilayer ceramic capacitors have insufficient lifetime characteristics despite improved breakdown voltage and capacitance-temperature characteristics, limiting their reliability.
Innovation Solution
Incorporating a composite oxide expressed by M4R6O(SiO4)6, where M is Ca or Sr and R is a rare-earth element, into the dielectric ceramic composition, which diffuses near the surface of dielectric particles to form a diffusive phase, enhancing breakdown voltage and lifetime characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dielectric ceramic composition with M4R6O(SiO4)6-type crystal phase is used to improve breakdown voltage, then breakdown voltage is improved, but lifetime characteristic is insufficient
Solution Approach 1:
The invention changes the chemical composition parameters by introducing specific rare-earth elements (La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu) in controlled amounts (0.01-5 wt% each) into the M4R6O(SiO4)6 crystal phase. This compositional modification transforms the grain boundary phase characteristics, simultaneously improving both breakdown voltage and lifetime characteristic without sacrificing one for the other.
Solution Approach 2:
The invention creates a composite grain boundary phase structure where M4R6O(SiO4)6-type crystal phase is formed with specific rare-earth element combinations. This composite material approach at the grain boundary level produces synergistic effects that enhance both electrical strength (breakdown voltage) and long-term reliability (lifetime characteristic) beyond what single-element additions could achieve.
2Strength
If M4R6O(SiO4)6-type crystal phase is precipitated uniformly in triple point grain boundary phase, then breakdown voltage is improved, but manufacturing complexity increases
Solution Approach 1:
The invention incorporates rare-earth element oxides into the initial raw material mixture before sintering, allowing the M4R6O(SiO4)6-type crystal phase to form automatically during the standard two-stage sintering process. This preliminary incorporation eliminates the need for separate grain boundary phase formation steps, reducing manufacturing complexity while achieving uniform precipitate distribution.
Solution Approach 2:
The invention modifies the chemical composition parameters of the raw materials to include specific rare-earth element oxides (0.01-5 wt% each), which changes the phase formation behavior during sintering. This compositional adjustment enables the M4R6O(SiO4)6-type crystal phase to precipitate uniformly in the triple point grain boundary phase under standard sintering conditions, avoiding complex additional processing steps.
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 significantly improves breakdown voltage and lifetime characteristics while maintaining specific permittivity, dielectric loss, and capacitance-temperature characteristics, leading to more reliable electronic devices.
Implementation Method 1
Incorporating a composite oxide expressed by M4R6O(SiO4)6, where M is Ca or Sr and R is a rare-earth element, into the dielectric ceramic composition, which diffuses near the surface of dielectric particles to form a diffusive phase
Implementation Method 2
the obtained dielectric powder is fired in a reduced atmosphere, followed by heat treatment under an atmosphere with higher oxygen concentration than the reduced atmosphere
Data Source
AI summary
A production method of a dielectric ceramic composition at least including a main component including a dielectric oxide having perovskite-type crystal structure expressed by a formula ABO3 (note that in the formula, “A” indicates one or more elements selected from Ba, Ca, Sr and Mg, and that “B” indicates one or more elements selected from Ti, Zr and Hf) comprises steps of preparing a main component material including said dielectric oxide expressed by ABO3; preparing a subcomponent material including a composite oxide expressed by M4R6O(SiO4)6 (note that “M” indicates at least one selected from Ca and Sr, and that “R” indicates at least one selected from Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu); mixing said main component material and subcomponent material to obtain a dielectric ceramic composition material; and firing said dielectric ceramic composition material.