Laser-Modified BaTiO3 Electrode Formation on Ceramic Capacitors
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Solution Overview
Problem
Existing methods for forming electrodes on ceramic electronic components, such as those using electrode paste or electroless plating, face issues of increased component size, complex manufacturing processes, high costs, and limited electrode formation regions, particularly when dealing with titanium-containing metal oxides like BaTiO3 used in multilayer ceramic capacitors.
Innovation Solution
A method involving pulse-laser irradiation of a ceramic base body containing titanium-based metal oxides to create a low-resistance section with specific peak power density and frequency parameters, allowing for electroplating of electrodes on these sections without cracking or abrasion, enabling efficient and cost-effective electrode formation in targeted regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrode paste is applied to form outer electrodes, then electrodes can be formed on ceramic base body, but the thickness of the electrode is increased and the external dimensions of the electronic component are increased
Solution Approach 1:
The patent replaces the mechanical application method (paste coating) with a chemical deposition method (electroless plating). Instead of physically applying paste that adds thickness, the invention uses chemical reactions to deposit metal layers directly on the ceramic surface, eliminating the need for thick paste layers and subsequent firing processes.
Solution Approach 2:
The invention changes the fundamental parameters of electrode formation by using electroless plating conditions (chemical bath deposition) instead of paste application parameters (screen printing, thickness control). This allows for precise control of electrode thickness at the micrometer level without adding significant external dimensions.
2Manufacturing precision
If electroless plating is used to form outer electrodes by exposing inner electrode end portions and anchor tabs, then plated electrodes can be formed, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The invention extracts and eliminates the unnecessary anchor tabs from the manufacturing process. By using inner electrode end portions alone as plating nuclei, the patent removes the complex step of forming and positioning separate anchor tabs, thereby simplifying the overall manufacturing process while maintaining precise electrode formation.
Solution Approach 2:
The inner electrode end portions serve multiple functions: they act as both the exposed electrode terminals and the nuclei for electroless plating deposition. This multi-functionality eliminates the need for separate anchor tabs, reducing process complexity while achieving the same plating initiation purpose.
3Manufacturing precision
If electroless plating is used with exposed inner electrode end portions, then plated electrodes can be formed, but the regions where the outer electrodes are formed are limited
Solution Approach 1:
The invention introduces an intermediary substance (sensitivity-enhancing coating or catalytic layer) on the ceramic base body surface that facilitates electroless plating deposition. This intermediary allows plating to occur on regions beyond just the inner electrode end portions, enabling flexible electrode formation on various surface areas of the ceramic component.
Solution Approach 2:
The patent applies different surface treatments or sensitivity-enhancing coatings to specific regions of the ceramic base body to control where plating occurs. By modifying local surface properties, the invention enables precise control over electrode formation regions while maintaining the ability to form electrodes on diverse areas of the component surface.
4Manufacturing precision
If laser irradiation is used to form low-resistance sections on ferrite-containing ceramic, then plated electrodes can be formed in given regions, but the method is not suitable for titanium-containing metal oxides like BaTiO3
Solution Approach 1:
The invention changes the material composition parameter of the ceramic base body by incorporating titanium-containing metal oxides (such as BaTiO3) alongside or instead of ferrite. This material substitution enables the ceramic to respond appropriately to laser irradiation for low-resistance section formation, expanding the method's applicability to different ceramic types used in electronic components.
Solution Approach 2:
The patent creates a composite ceramic material system that combines titanium-containing metal oxides with other ceramic components. This composite approach leverages the favorable properties of titanium-based materials for laser-induced low-resistance formation while maintaining the overall functional requirements of the ceramic electronic component.
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 allows for the formation of plated electrodes on ceramic electronic components with reduced resistance and improved plating deposition properties, suppressing crack generation and abrasion, thus enabling efficient and cost-effective electrode formation in specific areas, particularly for multilayer ceramic capacitors.
Implementation Method 1
forming a low-resistance section by modifying the metal oxide through irradiation of part of a surface layer portion of the ceramic base body with a pulse laser
Implementation Method 2
irradiation with the pulse laser is performed with a peak power density of 1×10^6 W/cm^2 to 1×10^9 W/cm^2
Implementation Method 3
forming an electrode on the low-resistance section by electroplating
Data Source
AI summary
A method for manufacturing a ceramic electronic component in which a plated electrode can be formed in a region of the surface of a ceramic base body formed of a titanium-containing metal oxide. The method includes preparing a ceramic base body containing a titanium-containing metal oxide, forming a low-resistance section by modifying the metal oxide through irradiation of part of a surface layer portion of the ceramic base body with a pulse laser with a peak power density of 1×106 W/cm2 to 1×109 W/cm2 and a frequency of 500 kHz or less, and forming an electrode on the low-resistance section by electroplating. The laser irradiation generates an O defect in a titanium-containing metal oxide, such as BaTiO3 to form an n-type semiconductor. Since this semiconductor section has a lower resistance value than the metal oxide, plating metal can be selectively deposited by electroplating.