Doped Ceramic Composition for Miniaturized ESD-Resistant Components
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Solution Overview
Problem
Conventional ceramic components face challenges in miniaturization, as size reduction can lead to increased sensitivity to electrostatic discharges (ESD), rendering them unusable, and existing materials do not effectively maintain electrical properties at reduced sizes.
Innovation Solution
A ceramic component with a base body composed of a ceramic material with the empirical formula AxByC1-x-vTi1-y+wO3*(Mn2P2O7)z*Du, incorporating specific dopants and additives, including manganese pyrophosphate, which allows for reduced sintering temperatures and improved electrical and mechanical properties, and the use of nickel-containing inner electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of ceramic structural parts is reduced to meet miniaturization requirements, then the component dimensions are reduced, but the sensitivity to electrostatic discharges increases and electrical properties deteriorate
Solution Approach 1:
The patent modifies the chemical composition parameters of the ceramic material by incorporating specific dopants (lanthanum, neodymium, praseodymium, cerium at 0.01-5 at%, niobium, tantalum, vanadium at 0.01-5 at%) and manganese pyrophosphate (0.1-10 wt%) to change the electrical and mechanical properties of the ceramic, enabling miniaturization while maintaining reliability
Solution Approach 2:
The patent creates a composite ceramic material system combining base ceramic (calcium, strontium, or barium titanate) with multiple dopants and manganese pyrophosphate additives, forming a multi-component composite that achieves both small size and high reliability through synergistic effects
2Ease of manufacture
If conventional ceramic materials are used in miniaturized components, then manufacturing is simpler, but the components become more sensitive to electrostatic discharges and less reliable
Solution Approach 1:
Manganese pyrophosphate acts as an intermediary additive that modifies the sintering process and grain boundary properties, reducing ESD sensitivity without complicating the manufacturing process. The additive incorporates during standard sintering (1200-1400°C) and provides protective effects at grain boundaries
3Temperature
If sintering temperature is reduced to lower manufacturing costs, then production costs decrease, but material density and mechanical strength may be compromised
Solution Approach 1:
Manganese pyrophosphate serves as a sintering aid that enables effective sintering at lower temperatures (1200-1400°C) by promoting grain boundary diffusion and liquid phase sintering, achieving both cost reduction and maintained mechanical strength
Solution Approach 2:
The patent optimizes the sintering temperature parameter to the range of 1200-1400°C, which is lower than conventional sintering temperatures, while compensating for the reduced temperature effect through controlled dopant addition and extended sintering time (2-24 hours)
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 solution provides a robust and cost-effective ceramic component that is resistant to ESD, maintaining performance even at smaller sizes, with improved electrical and mechanical properties due to controlled grain growth and the use of cost-effective nickel electrodes.
Implementation Method 1
The ceramic material allows for reduced sintering temperatures and improved electrical and mechanical properties
Implementation Method 2
Mn2P2O7, which allows for reduced sintering temperatures
Implementation Method 3
A is a first doping which is selected from a group of first metals comprising neodymium, praseodymium, cerium and lanthanum. Further, B is a second doping which is selected from a group of second metals comprising niobium, tantalum and vanadium
Implementation Method 4
a ceramic component having a ceramic base body (1) which contains a ceramic material as the main constituent
Data Source
AI summary
A ceramic component having a ceramic main part containing AxByC1−x−vTi1−y+wO3*(Mn2P2O7)z*Du, in which A is a first dopant selected from a group including neodymium, praseodymium, cerium, and lanthanum, B is a second dopant selected from a group including niobium, tantalum, and vanadium, C is selected from a group including calcium, strontium, and barium, and D includes a metal selected from a group including aluminum, nickel, and iron. x is the proportion of A, y is the proportion of B, v is the proportion of A vacancies, w is the proportion of excess titanium, z is the proportion of Mn2P2O7, u is the proportion of D, and the following applies: 0.0≤x<0.1, 0.0≤y<0.1, 0≤v<1.5*x, 0≤w<0.05, 0.01≤z<0.1, 0≤u<0.05. A method for producing the ceramic component is also disclosed.