Dielectric Composition Crack Restraint via Segregation Phase
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Solution Overview
Problem
Existing dielectric compositions, such as those with CaTiO3 and CaZrO3, fail to adequately restrain crack generation in hot and humid environments, which affects the reliability of electronic components like multilayer ceramic capacitors.
Innovation Solution
A dielectric composition with a main phase of ABO3, where A includes calcium or strontium and B includes zirconium, titanium, or hafnium, combined with a Ca—Zr—Si—O segregation phase that includes calcium, zirconium, and silicon, effectively restraining crack generation by incorporating specific mole ratios and crystal structures to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric composition with CaTiO3 and CaZrO3 main crystal phase is used, then the dielectric characteristics are improved, but crack generation occurs in hot and humid environments
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a specific Ca-Zr-Si-O segregation phase with controlled amounts of zirconium (0.12-0.50 parts by mol), calcium (0.16-0.77 parts by mol), silicon (0.08-0.45 parts by mol), and optionally strontium (0.00-0.30 parts by mol). This compositional modification creates a secondary phase that restrains crack generation in hot and humid environments while maintaining dielectric characteristics.
Solution Approach 2:
The patent creates a composite dielectric material consisting of a main crystal phase (CaTiO3-CaZrO3 system) and a secondary Ca-Zr-Si-O segregation phase. This composite structure combines the dielectric properties of the main phase with the crack-restraining properties of the segregation phase, achieving both electrical performance and environmental reliability.
2Productivity
If dielectric layer thickness is reduced to improve performance, then component size and capacitance density are improved, but reliability decreases due to increased susceptibility to cracks
Solution Approach 1:
The patent modifies the material composition parameters to include the Ca-Zr-Si-O segregation phase, which provides crack restraint even in thin dielectric layers. This allows reduction of dielectric layer thickness for improved capacitance density while the segregation phase prevents crack propagation that would normally occur in thinner layers.
Solution Approach 2:
The Ca-Zr-Si-O segregation phase acts as a preventive measure against crack formation and propagation. By incorporating this phase beforehand in the material composition, the patent creates a buffer that restrains crack development during subsequent thermal and humid stress, enabling thinner layers to maintain reliability.
Data Source
AI summary
A dielectric composition includes a main phase and a Ca—Zr—Si—O segregation phase. The main phase includes a main component expressed by ABO3. “A” includes at least one selected from calcium and strontium. “B” includes at least one selected from zirconium, titanium, hafnium, and manganese. The Ca—Zr—Si—O segregation phase includes at least calcium, zirconium, and silicon. The Ca—Zr—Si—O segregation phase includes 0.12-0.50 parts by mol of zirconium, provided that a total of calcium, strontium, silicon, and zirconium included in the Ca—Zr—Si—O segregation phase is 1 part by mol.