Dielectric Ceramic Composition with Segregated Particles for Capacitor Reliability
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Solution Overview
Problem
Laminated ceramic capacitors face reliability issues when miniaturized, as the dielectric layer thinning leads to increased electric field intensity and decreased reliability, especially in high-temperature and high-voltage environments.
Innovation Solution
A dielectric ceramic composition with a core-shell structure and segregated particles, where the concentration of rare earth elements in segregated particles is higher than in the shell portion, and the area occupied by these particles is limited, enhancing temperature characteristics and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the dielectric layer is thinned to miniaturize the laminated ceramic capacitor, then the device size is reduced, but the electric field intensity increases and reliability decreases
Solution Approach 1:
The patent applies local quality by creating segregated particles with high rare earth element concentration in specific regions of the dielectric layer. These localized regions with enhanced properties (higher reliability) are distributed throughout the thinned dielectric layer, allowing the overall device to be miniaturized while maintaining reliability in critical areas through the strategically positioned segregated particles.
2Quantity of substance
If the dielectric layer is thinned to increase capacitance density, then the capacitance per unit volume increases, but the insulation resistance decreases due to increased electric field intensity
Solution Approach 1:
The patent employs composite materials by combining the base dielectric ceramic with segregated particles containing high concentrations of rare earth elements. This composite structure allows the thinned dielectric layer to achieve high capacitance density while the rare earth-enriched segregated particles provide localized regions of high insulation resistance, counteracting the harmful effects of increased electric field intensity.
3Quantity of substance
If the number of laminated layers is increased to maintain capacitance, then the total capacitance is maintained, but the device height increases and reliability in high-temperature environments decreases
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and microstructure of the dielectric layer through the introduction of segregated particles with high rare earth element concentration. This changes the electrical and thermal parameters of the dielectric material, enabling high capacitance to be achieved in fewer, thicker layers rather than many thin layers, thereby improving high-temperature reliability while maintaining total capacitance.
Data Source
AI summary
A dielectric ceramic composition including a main component having a perovskite crystal structure expressed by general formula ABO3, a first sub-component of an oxide of a rare earth element, and a second sub-component of an oxide of Si, and at least dielectric particles having a core-shell structure and segregated particles, in which a concentration of the rare earth element in the segregated particles is two or more times an average concentration of the rare earth element in a shell portion of the dielectric particles having the core-shell structure, and an area of the region occupied by the segregated particles is 5.0% or less and an average of cross-sectional areas of the respective segregated particles is 0.075 μm2 or less in a cross-section obtained by cutting the dielectric ceramic composition.