Electrode Embedded Ceramic Structure Delamination Prevention
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Solution Overview
Problem
Conventional electrode embedded ceramic structures face a trade-off between characteristics and durability, with thickening the protective ceramic layer improving durability but degrading device performance, and thinning it reducing durability and increasing delamination risks.
Innovation Solution
A new electrode embedded ceramic structure design featuring a thinner second ceramic layer with specific length ratios and the inclusion of ceramic particles in the electrode layer, which enhances bonding and durability while maintaining device performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second ceramic layer is thickened to improve durability, then the durability is improved, but the device characteristics are degraded
Solution Approach 1:
The invention changes the geometric parameters of the electrode layer, specifically setting the sum of the lengths of the front and back surfaces (L1+L2) to be 2.2 times or more of the length in the direction orthogonal to the laminating direction (L3). This parameter optimization allows the electrode layer to provide sufficient bonding area for durability while maintaining a thin overall structure that preserves device characteristics.
Solution Approach 2:
The invention uses a composite structure where the electrode layer contains ceramic particles (at least 4% by volume) mixed with the electrode material. This composite composition enhances the bonding strength between the electrode layer and ceramic layers, improving durability without requiring a thick protective layer that would degrade device performance.
2Productivity
If the second ceramic layer is thinned to maintain device characteristics, then the device characteristics are maintained, but delamination easily occurs
Solution Approach 1:
The invention addresses the delamination problem by optimizing the electrode layer's geometry in multiple dimensions. By configuring the electrode layer with extended front and back surfaces (L1 and L2) that satisfy (L1+L2)/L3≥2.2, the bonding area is significantly increased without increasing the overall thickness of the protective layer, thus preventing delamination while maintaining thin structure benefits.
Solution Approach 2:
The composite electrode layer containing ceramic particles (at least 4% by volume) provides enhanced mechanical bonding and interfacial adhesion between the electrode and ceramic layers. This composite structure prevents delamination even when the second ceramic layer is thin, allowing the device to maintain both good characteristics and high reliability.
3Strength
If ceramic particles are added to the electrode layer, then the bonding strength is improved, but the electrode layer complexity increases
Solution Approach 1:
The invention optimizes the ceramic particle content to be at least 4% by volume in the electrode layer. This specific parameter threshold provides sufficient bonding enhancement through ceramic particle reinforcement while avoiding excessive complexity in electrode layer fabrication and processing.
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 design effectively prevents delamination and improves durability by creating a robust anchor effect between the electrode and ceramic layers, allowing for high thermal stability and prolonged device lifespan.
Implementation Method 1
the electrode layer may contain ceramic particles. A percentage of ceramic particles in the electrode layer may be higher than or equal to 4%
Data Source
AI summary
An electrode embedded ceramic structure includes: a first ceramic layer; an electrode layer formed on the first ceramic layer; and a second ceramic layer covering the first ceramic layer and the electrode layer, the second ceramic layer being thinner than the first ceramic layer. In a cross section of the first ceramic layer, the electrode layer, and the second ceramic layer along a laminating direction in this electrode embedded ceramic structure, L1, L2, and L3 satisfy (L1+L2)/L3≥2.2, where L1 denotes a length of the electrode layer on the first ceramic layer, L2 denotes a length of the electrode layer on the second ceramic layer, and L3 denotes a length of the electrode layer in a direction orthogonal to the laminating direction.