Multi-Layer Ceramic Capacitor Asymmetric Side Margins
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Solution Overview
Problem
Multi-layer ceramic capacitors experience performance reduction due to stress applied during sintering, as side margins and the multi-layer unit exhibit different contraction behaviors, leading to discontinuity of internal electrodes.
Innovation Solution
The multi-layer ceramic electronic component is designed with first and second side margins that have varying average thicknesses in different regions, applying inclined tensile stress during sintering to control grain growth and maintain electrode continuity, while maintaining a general rectangular shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If side margins are provided in a later step to protect side surfaces, then reliability is improved, but manufacturing precision deteriorates due to different contraction behaviors during sintering
Solution Approach 1:
The side margins are designed with non-uniform thickness distribution, where the thickness varies in the vertical direction. Specifically, the side margins have greater thickness at certain regions and lesser thickness at other regions, creating local quality variations that generate compensating stress during sintering to maintain overall dimensional precision.
Solution Approach 2:
The side margins exhibit asymmetric thickness distribution rather than uniform symmetry. The thickness profile is deliberately designed to be asymmetric in the vertical direction, creating differential contraction forces that counteract the inherent contraction differences between side margins and multi-layer units during sintering.
2Ease of manufacture
If uniform thickness side margins are used, then ease of manufacture is improved, but manufacturing precision deteriorates due to stress-induced grain growth
Solution Approach 1:
Instead of uniform thickness, the side margins are designed with location-specific thickness variations. The thickness is intentionally made non-uniform in the vertical direction, with different thicknesses at different heights, creating local quality differences that control grain growth patterns and prevent electrode discontinuity.
3Ease of manufacture
If side margins have low density, then ease of manufacture is improved, but manufacturing precision deteriorates due to excessive contraction
Solution Approach 1:
The thickness parameter of the side margins is deliberately changed and optimized to create a specific thickness distribution profile. By adjusting the thickness parameter in the vertical direction, the contraction behavior during sintering is controlled to achieve dimensional stability despite the low density of the side margins.
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 configuration suppresses the reduction in performance by ensuring continuity of internal electrodes in the in-plane direction, effectively managing stress-induced grain growth and maintaining capacitance.
Implementation Method 1
During sintering in the process of producing the multi-layer ceramic electronic component, a force caused by the contraction of the first side margin and the second side margin is applied to the first side surface and the second side surface of the multi-layer unit
Implementation Method 2
in the multi-layer unit, the crystal constituting the first and second internal electrodes is likely to cause grain growth along the direction of the tensile stress applied to the inside of the multi-layer unit
Data Source
AI summary
A multi-layer ceramic electronic component includes: a multi-layer unit including ceramic layers laminated in a direction of a first axis, internal electrodes disposed between the ceramic layers, and first and second side surfaces on which end portions of the internal electrodes in a direction of a second axis orthogonal to the first axis are positioned; and first and second side margins that cover the first and second side surfaces, respectively. When the first and second side margins are each divided equally into first and second regions along a plane perpendicular to the direction of the first axis, the first side margin has a larger average thickness in the first region than in the second region, and the second side margin has a larger average thickness in the second region than in the first region.