Multilayer Ceramic Capacitor Core-Shell Grains for Narrow Size Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming dielectric crystal grains with uniform size in multilayer ceramic capacitors face challenges in achieving uniform dispersion and reliability due to limitations in dispersibility and coating uniformity, leading to high size dispersion and reduced electrical characteristics.
Innovation Solution
The method involves coating dielectric particles with additive elements in an ionic state, using a liquid-phase pre-diffusion process to achieve a core-shell structure with a uniform size distribution and controlled grain growth, enhancing the reliability and electrical characteristics of multilayer electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If organic dispersant in organic solvent is used to disperse dielectric powder and additive particles, then dispersion is improved, but manufacturing complexity and environmental concerns increase
Solution Approach 1:
The patent changes the chemical state of additives from molecular/organic form to ionic form, and uses water as solvent instead of organic solvent. This parameter change enables effective dispersion without complex organic dispersants, resolving the contradiction between achieving uniform dispersion and simplifying manufacturing process.
Solution Approach 2:
The patent replaces chemical dispersants (organic dispersants in organic solvents) with a physical/chemical ionic mechanism where additive ions naturally disperse and adsorb onto dielectric particle surfaces through electrostatic interactions, eliminating the need for complex dispersant systems.
2Manufacturing precision
If coating dielectric powder with additive is performed to achieve uniform size, then crystal grain uniformity is improved, but coating uniformity and dispersion quality deteriorate due to aggregation
Solution Approach 1:
The patent changes additives from neutral molecular form to ionic form, enabling them to dissolve and disperse uniformly in water before adsorption. This ionic state prevents aggregation during the coating process, achieving both uniform coating thickness and good dispersion, thus resolving the contradiction between coating uniformity and dispersion quality.
Solution Approach 2:
Water acts as an intermediary medium that facilitates uniform dispersion of ionic additives before they adsorb onto dielectric particles. The water-based slurry allows additive ions to distribute evenly throughout the mixture, preventing direct particle-to-particle contact and aggregation, thereby achieving uniform coating without compromising dispersion.
3Volume of moving object
If miniaturization of multilayer ceramic capacitors is pursued, then device size is reduced, but reliability decreases due to higher stress and manufacturing difficulties
Solution Approach 1:
The patent uses ionic additives in water-based slurries to achieve superior control over crystal grain growth during sintering. This enables precise control of dielectric layer thickness and grain uniformity even at miniaturized scales, maintaining reliability while reducing device size by ensuring uniform microstructure formation in thin layers.
Solution Approach 2:
The patent uses water-based slurries (hydraulic medium) to achieve uniform particle distribution and controlled green sheet formation. The water-based system provides better flow characteristics and uniformity during tape casting, enabling precise control of layer thickness and composition in miniaturized capacitors, thereby maintaining reliability at smaller sizes.
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
This approach results in dielectric crystal grains with a narrow size distribution and improved reliability, contributing to enhanced electrical characteristics and reduced dispersion, thus addressing the limitations of existing methods.
Implementation Method 1
adsorbing additives in the form of elements or ions into dielectric particles
Implementation Method 2
firing the additives
Implementation Method 3
forming dielectric crystal grains
Implementation Method 4
uniformly dissolving and diffusing sub-components in dielectric particles
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A multilayer electronic component includes: a body including a dielectric layer and an internal electrode; and an external electrode disposed outside the body and connected to the internal electrode, in which the dielectric layer includes a plurality of dielectric crystal grains, and at least one of the plurality of dielectric crystal grains includes a core-shell structure including an inner core area and a shell area covering at least a portion of the core area, and 90% or more of the plurality of dielectric crystal grains satisfy an average size of 170.0 nm to 190.0 nm, and a maximum deviation of sizes of the dielectric crystal grains satisfies ± 60.0 nm compared to an average size of the dielectric crystal grains.