Dielectric Composition Crack Resistance 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 and B includes zirconium, titanium, or hafnium, combined with a Ca—Si—P—O segregation phase, which includes calcium, silicon, and phosphorus, effectively inhibiting crack formation by creating a secondary phase that restricts crack progression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric composition with main components of CaTiO3 and CaZrO3 is used, then the dielectric characteristics are improved, but the restraint effect on crack generation in hot and humid environment is insufficient
Solution Approach 1:
The patent applies composite materials by combining CaTiO3 and CaZrO3 in specific proportions (0.5-9.5 mol% CaTiO3 and 90.5-99.5 mol% CaZrO3) to create a dielectric composition that exhibits both improved dielectric characteristics and enhanced restraint effect against crack generation in hot and humid environments, resolving the contradiction between reliability and composition complexity
Solution Approach 2:
The patent employs parameter changes by precisely controlling the molar proportions of CaTiO3 and CaZrO3 components, along with adding specific sintering aids (Bi2O3: 0.1-5.0 wt%, B2O3: 0.1-5.0 wt%, SiO2: 0.1-5.0 wt%), to optimize the dielectric properties and crack resistance without excessive complexity in the composition formulation
2Productivity
If the dielectric layer thickness is reduced to improve capacitor performance, then the productivity and capacitance density are improved, but the crack generation risk increases in hot and humid environment
Solution Approach 1:
The patent applies parameter changes by optimizing the dielectric layer thickness to 1 μm or less while simultaneously adjusting the composition parameters (CaTiO3:CaZrO3 ratio and sintering aid content) to maintain crack resistance, thereby achieving both improved productivity through thinner layers and sustained reliability through compositional optimization
Solution Approach 2:
The patent uses composite materials with specific CaTiO3-CaZrO3 ratios and sintering aids to enhance the mechanical strength and crack resistance of ultra-thin dielectric layers (1 μm or less), enabling high capacitance density and productivity without sacrificing reliability in hot and humid conditions
Data Source
AI summary
A dielectric composition includes a main phase and a Ca—Si—P—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—Si—P—O segregation phase includes at least calcium, silicon, and phosphorus.