Multilayer Ceramic Capacitor Doped Additive Gradient
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges in achieving high capacitance and reliability due to insulation deterioration and poor reduction resistance in barium titanate-based dielectric materials, especially when subjected to high temperatures, leading to potential disconnection of internal electrodes and decreased connectivity.
Innovation Solution
Incorporating a dielectric material doped with additives such as calcium, valence acceptor elements, and rare earth elements within the internal electrodes and dielectric layers, with a concentration gradient where the additive is higher at the interfaces between dielectric layers and internal electrodes, enhancing reduction resistance and insulating characteristics while maintaining high permittivity and low dielectric loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If barium titanate-based dielectric materials are used in multilayer ceramic capacitors, then high capacitance can be achieved, but insulation deterioration occurs and reliability decreases due to poor reduction resistance at high temperatures
Solution Approach 1:
The patent applies local quality by creating a concentration gradient of dopant elements (such as rare earth elements, valence acceptor elements, or calcium) within the dielectric layer. The dopant concentration is higher at the interface between the internal electrode and dielectric layer, and decreases toward the center of the dielectric layer. This localized distribution improves reduction resistance at the critical interface region where insulation deterioration typically occurs, while maintaining high capacitance through the overall dielectric material composition.
2Manufacturing precision
If high temperature processing is applied to manufacture multilayer ceramic capacitors, then sintering and connectivity can be improved, but internal electrode disconnection occurs due to poor reduction resistance
Solution Approach 1:
The patent applies preliminary action by pre-doping the dielectric material with specific elements (rare earth elements, valence acceptor elements, or calcium) before the sintering process. This preliminary doping enhances the reduction resistance of the dielectric layer, particularly at the interface regions, so that when high-temperature sintering is subsequently applied, the internal electrodes maintain their connectivity without disconnection. The dopant elements are incorporated into the dielectric green sheets before stacking and sintering.
3Ease of manufacture
If uniform dopant distribution is used in dielectric layers, then manufacturing simplicity is maintained, but high permittivity and low dielectric loss cannot be simultaneously achieved
Solution Approach 1:
The patent implements local quality by establishing a non-uniform dopant distribution profile within the dielectric layer. The dopant concentration varies through the thickness of the dielectric layer, being highest at the interface with the internal electrode and decreasing toward the center. This gradient distribution optimizes both permittivity and dielectric loss by concentrating dopant elements where they most effectively improve electrical properties (at the interface), while avoiding excessive dopant content in the bulk that would increase dielectric loss.
Data Source
AI summary
A multilayer ceramic electronic component and a method of manufacturing the same are provided. The multilayer ceramic electronic component includes: a ceramic body including dielectric layers; and internal electrodes disposed on the dielectric layers within the ceramic body and containing a ceramic material trapped therein. The ceramic material is a dielectric material doped with an additive.