Multilayer Ceramic Capacitor Electrode Continuity via Grain Size Control
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Solution Overview
Problem
The miniaturization of electronic products has led to challenges in maintaining uniform and continuous inner electrode layers in multilayer ceramic electronic components, resulting in disconnection issues and deteriorated insulating properties, which affect the reliability of these components.
Innovation Solution
A multilayer ceramic electronic component design with a dielectric layer thickness of 0.6 μm or less, featuring contact and non-contact dielectric grains, and inner electrode layers with a continuity of 80% or more, where the average diameter of contact dielectric grains is less than 0.35 times the dielectric layer thickness, and non-contact dielectric grains' diameter is less than 0.25 times the dielectric layer thickness, ensuring improved connectivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If dielectric layers and inner electrode layers are thinned to increase capacitance, then capacitance increases, but inner electrode layers become disconnected and reliability deteriorates
Solution Approach 1:
The patent changes the particle size parameter of ceramic powder in the inner electrode paste, using a bimodal distribution with fine particles (0.5-2.0 μm) and coarse particles (3.0-6.0 μm). The fine particles fill gaps and improve continuity, while coarse particles provide structural framework, resolving the contradiction between thinning electrodes for higher capacitance and maintaining electrode continuity for reliability.
Solution Approach 2:
The patent creates a composite inner electrode structure by combining ceramic powder particles of different sizes (bimodal distribution) within the same electrode layer. This composite approach allows the electrode to maintain continuity and structural integrity even when thinned, enabling higher capacitance without sacrificing reliability.
2Quantity of substance
If dielectric layers are thinned to increase capacitance, then capacitance increases, but insulating properties deteriorate and reliability decreases
Solution Approach 1:
The patent optimizes the particle size distribution parameter of dielectric grains, controlling the average diameter to be 0.2-0.5 μm with a specific size distribution. This parameter control ensures that even in thinned dielectric layers, the grains maintain proper spacing and insulation, preventing short circuits while preserving high capacitance.
3Reliability
If fine-grain ceramic powders are used in inner electrode paste, then electrode continuity improves, but grain leakage into dielectric layer occurs and reliability deteriorates
Solution Approach 1:
The patent precisely controls the particle size parameter of ceramic powder in the inner electrode paste, using a bimodal distribution where fine particles (0.5-2.0 μm) improve continuity but coarse particles (3.0-6.0 μm) act as barriers. This parameter optimization prevents grain leakage into the dielectric layer during sintering while maintaining electrode continuity.
Solution Approach 2:
The patent applies local quality by having different particle sizes in different regions of the inner electrode paste. The fine particles are distributed to ensure continuity in critical areas, while coarse particles are positioned to prevent leakage into the dielectric layer, creating a functionally differentiated structure within the homogeneous paste.
Data Source
AI summary
There is provided a multilayer ceramic electronic component, including: a ceramic body including a dielectric layer having an average thickness of 0.6 μm or less; and first and second inner electrode layers within the ceramic body, disposed to face each other with the dielectric layer interposed therebetween, wherein the dielectric layer includes contact dielectric grains in contact with the first or second inner electrode layer and non-contact dielectric grains not in contact with the first or second inner electrode layer, and, when an average thickness of the dielectric layer is defined as td and an average diameter of the contact dielectric grains is defined as De, De/td≦0.35 is satisfied. The multilayer ceramic electronic component has improved continuity of the inner electrode layer, large capacitance, extended accelerated lifespan and excellent reliability.