Graphene Intermediate Layers in MLCCs to Prevent Electrostrain Cracks
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Solution Overview
Problem
Multilayer ceramic capacitors face reliability issues due to electrostrain cracks caused by stress from applied voltages, and existing methods to enhance strength often result in excessive capacitance reduction.
Innovation Solution
Incorporating a graphene-based intermediate layer between capacitance forming portions, with a second dielectric layer containing graphene and a first dielectric layer without or with lower graphene content, to improve strength and reliability while maintaining capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a buffer ceramic layer is inserted into the center of the multilayer ceramic capacitor to improve strength, then the strength is improved, but the capacitance is excessively decreased due to the buffer ceramic layer having a relatively great thickness
Solution Approach 1:
The patent changes the material composition parameters of the intermediate layer by incorporating graphene (0.1-5 wt%) into the ceramic material. This parameter change allows the intermediate layer to achieve high strength with reduced thickness compared to conventional buffer ceramic layers, thereby minimizing the impact on capacitance while still providing the necessary mechanical reinforcement to prevent electrostrain cracks
Solution Approach 2:
The patent uses composite materials by combining graphene with ceramic materials (barium titanate, strontium titanate, or lead zirconate titanate) to create an intermediate layer that exhibits both high mechanical strength and electrical properties suitable for capacitor operation. The graphene-ceramic composite achieves superior strength-to-thickness ratio, allowing thin intermediate layers that do not significantly reduce capacitance
2Strength
If the thickness of the intermediate layer is increased to improve strength, then the strength is improved, but the capacitance is excessively decreased
Solution Approach 1:
The patent optimizes the thickness parameter of the intermediate layer to 1-10 μm, which is sufficiently thin to minimize capacitance reduction while incorporating graphene to achieve the necessary strength. The graphene content (0.1-5 wt%) is adjusted to ensure adequate mechanical reinforcement at this reduced thickness, preventing electrostrain cracks without requiring greater thickness
3Reliability
If a buffer ceramic layer is inserted to prevent electrostrain cracks, then reliability is improved, but the device complexity is increased
Solution Approach 1:
The patent merges the functions of the intermediate layer and buffer layer into a single integrated intermediate layer containing graphene. This merged structure provides both mechanical reinforcement (preventing electrostrain cracks) and electrical insulation functions, eliminating the need for separate buffer ceramic layers and reducing overall device complexity while maintaining high reliability
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 effectively prevents electrostrain cracks, enhances fracture toughness, and maintains capacitance by using graphene in the intermediate layer, reducing the need for thicker buffer layers that would otherwise decrease capacitance.
Implementation Method 1
The second dielectric layer includes graphene
Implementation Method 2
a plurality of capacitance forming portions including a first dielectric layer and an internal electrode
Implementation Method 3
the dielectric layer may have piezoelectricity in which a voltage is generated when a pressure is applied
Implementation Method 4
electrostrictive properties in which pressure is generated when a voltage is applied
Data Source
AI summary
A multilayer electronic component includes a plurality of capacitance forming portions including a first dielectric layer and an internal electrode disposed in a first direction, and an intermediate layer disposed between capacitance forming portions adjacent to each other and including a second dielectric layer, a body including first and second surfaces opposing each other in the first direction, third and fourth surfaces connected to the first and second surfaces and opposing each other in a second direction, and fifth and sixth surfaces connected to the first to fourth surfaces and opposing each other in a third direction; and an external electrode disposed on the body and connected to the internal electrode. The second dielectric layer includes graphene. The first dielectric layer does not include graphene, or includes graphene in a content less than a content of graphene included in the second dielectric layer.