Low-Chlorine Electronic Component Materials for Short-Circuit Reliability

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Solution Overview

Problem

Existing electronic components face issues with short circuit failure rates and reliability due to chlorine impurities, particularly when chlorine originates from inhibitors in electrode layer raw materials, which can react with conductive materials during the manufacturing process, affecting the properties and longevity of the components.

Innovation Solution

The electronic component is designed with a chlorine concentration of 10 ppm or less, using a raw material inhibitor with a chlorine concentration of 50 ppm or less and an average particle diameter of 100 nm or smaller, where the inhibitor's composition matches the main component of the functional layer, and incorporating conductive materials like nickel and copper, to minimize chlorine's impact and enhance adhesion and sintering properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chlorine concentration in raw materials is reduced, then reliability and lifetime are improved, but manufacturing complexity increases due to stricter material specifications

Engineering Contradiction:

Improveshort circuit failure rateVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent specifies precise parameter ranges for chlorine concentration (50 ppm or less in inhibitor, 10 ppm or less in element body) and particle diameter (100 nm or smaller) to achieve low short circuit failure rates while maintaining manufacturability through defined specifications

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses an inhibitor material as an intermediary substance that prevents chlorine from the conductive material from reacting with the dielectric layer, thereby protecting the overall structure while allowing the use of practical raw materials with manageable chlorine levels

Inventive Principle:

Principle #24Intermediary (Mediator)

2Duration of action of stationary object

If chlorine concentration is reduced to 10 ppm or less, then Highly Accelerated Lifetime Test is extended, but material selection and processing difficulty increase

Engineering Contradiction:

ImproveHighly Accelerated Lifetime TestVSAvoidmaterial processing ease

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The patent defines specific parameter thresholds (chlorine concentration ≤10 ppm in element body, particle diameter ≤100 nm) that balance lifetime performance with manufacturing feasibility through controlled material specifications

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies preliminary cleaning or selection of raw materials to ensure chlorine concentration and particle diameter meet specifications before manufacturing, preventing contamination rather than attempting remediation later

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11823839B2Electronic component

Publication Date: 2023.11.21 TDK CORP

AI summary

An electronic component includes an element body having a functional layer and an internal electrode layer, and an external electrode formed on a surface of the element body and connected to the internal electrode layer electrically. The chlorine concentration of the element body of the electronic component is 10 ppm or less.