Multilayer Ceramic Capacitor Internal Electrode Connectivity
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Solution Overview
Problem
Multilayer ceramic capacitors face issues with internal electrode disconnection, reduced capacitance, and increased internal stress due to mismatched contraction behavior between dielectric layers and electrodes, leading to reliability concerns and cracking during firing.
Innovation Solution
A multilayer ceramic electronic component with internal electrodes having a connectivity of 87% or greater, achieved by adjusting the particle size of nickel metal powder in the conductive paste and maintaining an average particle size distribution of 120 nm or less, along with a specific thickness range for dielectric and internal electrodes, to ensure effective connectivity and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of dielectric layers and internal electrodes is reduced to increase the number of stacked layers, then high capacitance and small size are achieved, but internal electrode disconnection and reduced capacitance occur due to thickness variation
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size distribution of nickel metal powder in the conductive paste. Specifically, it controls the average particle size (D50) to be 10 μm or less and the fine particle content (D10) to be 3 μm or less, which ensures uniform thickness of internal electrodes even when reduced, preventing disconnection while maintaining high capacitance through increased layer stacking.
Solution Approach 2:
The patent applies local quality by differentiating the particle size requirements for different regions of the conductive paste. It specifies that the fine particle content (D10) should be 3 μm or less while the average particle size (D50) should be 10 μm or less, creating a controlled distribution that ensures uniform electrode formation in critical areas while maintaining overall conductivity.
2Quantity of substance
If the thickness of dielectric layers and internal electrodes is reduced to increase the number of stacked layers, then high capacitance and small size are achieved, but internal cracks occur due to increased internal stress from mismatched contraction behavior
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution parameters (D50 ≤ 10 μm and D10 ≤ 3 μm) of the nickel metal powder. This results in internal electrodes with uniform thickness and reduced internal stress, preventing cracks during the contraction process while enabling high capacitance through increased layer stacking.
Solution Approach 2:
The patent applies beforehand cushioning by pre-controlling the particle size distribution of the conductive paste materials before manufacturing. This preventive measure ensures that internal electrodes maintain uniform thickness and proper adhesion from the outset, cushioning against the development of internal stresses that would otherwise lead to cracks during firing and contraction.
3Reliability
If residual carbonaceous materials are not easily removed due to fine grain of dielectric layer, then various types of cracks occur during firing, but removing them completely may affect the fine grain structure
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size distribution of nickel metal powder (D50 ≤ 10 μm, D10 ≤ 3 μm) in the conductive paste. This ensures complete removal of residual carbonaceous materials during firing while maintaining the fine grain structure of the dielectric layer, as the controlled particle size enables thorough combustion without disrupting the delicate ceramic matrix.
Data Source
AI summary
There is provided a multilayer ceramic electronic component including a ceramic body including a plurality dielectric layers stacked thereon, a plurality of internal electrodes formed to be exposed to both end surface of the ceramic body, having the dielectric layer interposed therebetween, and external electrodes formed on the end surfaces of the ceramic body and electrically connected to the internal electrodes, respectively, wherein connectivity of the internal electrode is equal to or greater than 87%.